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SEBM031303
MACHINE MODEL
SERIAL No.
PC750-7 PC750SE-7 PC750LC-7 PC800-7 PC800SE-7
20001 and up 20001 and up 20001 and up 40001 and up 40001 and up
•
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
•
PC750, 800-7 mounts the SAA6D140E-3 engine. For details of the engine, see the 6D140-3 Series Engine Shop Manual.
© 2004 All Rights Reserved Printed in Japan 09-04 (01)
00-1 (3)
GENERAL
CONTENTS No. of page
01 GENERAL ............................................................................................................................
01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD............................................
10-1
20 TESTING AND ADJUSTING ........................................................................
20-1
30 DISASSEMBLY AND ASSEMBLY
..................................................... 30-1
90 OTHERS ................................................................................................................................
00-2 (2)
90-1
PC750, 800-7
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SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •
Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK 11.When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
FOREWORD
GENERAL
FOREWORD GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models
REVISIONS
}
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
00-6
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
Symbol
Item
Remarks
k
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
5
Oil, water
Places where oil, water or fuel must be added, and the capacity.
6
Drain
Places where oil or water must be drained, and quantity to be drained.
a
4
3 2
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 •
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter
★
Allowable load
mm
kN
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 3
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
•
•
Disassembly
Type 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS ★ ★
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list. Category
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr
LT-1A
790-129-9030
150 g
Tube
• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
• Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.
LT-2
09940-00030
50 g
Polyethylene container
• Features: Resistance to heat and chemicals • Used for anti-loosening and sealant purpose for bolts and plugs.
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardening agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
• Used as heat-resisting sealant for repairing engine.
50 g
Polyethylene container
• Quick hardening type adhesive • Cure time: within 5 sec. to 3 min. • Used mainly for adhesion of metals, rubbers, plastics and woods.
Adhesives
Three bond 1735
790-129-9140
• Used as adhesive or sealant for metal, glass and plastic.
Aron-alpha 201
790-129-9130
2g
Polyethylene container
• Quick hardening type adhesive • Quick cure type (max. strength after 30 minutes) • Used mainly for adhesion of rubbers, plastics and metals.
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
• Resistance to heat, chemicals • Used at joint portions subject to high temperatures.
LG-1
790-129-9010
200 g
Tube
• Used as adhesive or sealant for gaskets and packing of power train case, etc.
LG-5
790-129-9080
1 kg
Can
• Used as sealant for various threads, pipe joints, flanges. • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
Tube
• Features: Silicon based, resistance to heat, cold • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc.
LG-6
790-129-9020
200 g
Gasket sealant LG-7
790-129-9070
1g
Tube
• Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.
Three bond 1211
790-129-9090
100 g
Tube
• Used as heat-resisting sealant for repairing engine.
Tube
• Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material • Used as sealing material for transfer case
Three bond 1207B
00-10
• Used as sealant for machined holes.
419-15-18131
100 g
FOREWORD
Molybdenum disulphide lubricant
Grease
Primer
Adhesive
Caulking material
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr
LM-G
09940-00051
60 g
Can
• Used as lubricant for sliding portion (to prevent from squeaking).
Tube
• Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc.
LM-P
09940-00040
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
200 g
• General purpose type Various
Various
Various
Various
• Used for normal temperature, light load bearing at places in contact with water or steam.
• Used for heavy load portion
Molybdenum disulphide grease LM-G (G2-M)
SYG2-400M SYG2-400M-A SYGA-16CNM
Hyper White Grease G2-T G0-T (*) *: For use in cold district
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)
400 g 16 kg
• Seizure resistance and heat resistance higher than molybdenum diBellows type sulfide grease Can • Since this grease is white, it does not stand out against machine body.
Biogrease G2B G2-BT (*) *: For high temperature and large load
SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
400 g 16 kg
Bellows type Can
SUNSTAR PAINT PRIMER 580 SUPER
20 ml
Glass container
SUNSTAR GLASS PRIMER 580 SUPER
20 ml
Glass container
400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can
417-926-3910
SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"
320 ml
Polyethylene container
Sika Japan, Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene container
SUNSTAR PENGUINE SEAL No. 2505
417-926-3920
320 ml
Polyethylene container
SEKISUI SILICONE SEALANT
20Y-54-55130
333 ml
Polyethylene container
• Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants. • Used as primer for cab side (Using limit: 4 months) • Used as primer for glass side (Using limit: 4 months) Adhesive for cab glass
Category
COATING MATERIALS
• "S" is used for high-temperature season (April - October) and "W" for low-temperature season (November - April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months)
00-11
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12 14
10 13 17 19 22
11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190
1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5
16 18 20 22 24
24 27 30 32 36
235 – 285 320 – 400 455 – 565 610 – 765 785 – 980
23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100
27 30 33 36 39
41 46 50 55 60
1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630
118 – 147 155 – 195 200 – 250 250 – 310 295 – 370
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12
10 13 14 27
5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2
0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2
Tightening torque
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49
2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5
00-12
Tightening torque
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
59 – 74 98 – 123 235 – 285
6 – 7.5 10 – 12.5 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
mm
mm
14 20 24 33 42
Varies depending on type of connector.
Tightening torque (Nm {kgm})
Norminal No.
02 03, 04 05, 06 10, 12 14
Range 35 – 63 84 – 132 128 – 186 363 – 480 746 – 1010
{3.5 – 6.5} {8.5 – 13.5} {13.0 – 19.0} {37.0 – 49.0} {76.0 – 103}
Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
mm
mm
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 — 36 — —
Tightening torque (Nm {kgm})
Norminal No.
08 10 12 14 16 18 20 24 30 33 36 42 52
Range 5.88 – 8.82 9.8 – 12.74 14.7 – 19.6 19.6 – 24.5 24.5 – 34.3 34.3 – 44.1 44.1 – 53.9 58.8 – 78.4 93.1 – 122.5 107.8 – 147.0 127.4 – 176.4 181.3 – 240.1 274.4 – 367.5
{0.6 – 0.9} {1.0 – 1.3} {1.5 – 2.0} {2.0 – 2.5} {2.5 – 3.5} {3.5 – 4.5} {4.5 – 5.5} {6.0 – 8.0} {9.5 – 12.5} {11.0 – 15.0} {13.0 – 18.0} {18.5 – 24.5} {28.0 – 37.5}
Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
10 0 2 24 0 4 43 0 6 77 0 12
6 8 10 12
1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
802 10 0 2 12 0 2 24 0 4 36 0 5
6 8 10 12 14
0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter
Tightening torque
inch
Nm
kgm
301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9
1 / 16 1/8 1/4 3/8 1/2 3/4 1
0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.41 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats
Taper seal type
Face seal type
Nominal thread Thread size size Root diameter - Threads per (mm) inch, Thread series (mm) (Reference)
Range
Target
19
34 - 63 {3.5 - 6.5}
44 {4.5}
14
9 – - 18UNF 16
14.3
22
54 - 93 {5.5 - 9.5}
74 {4.5}
–
11 – - 16UN 16
17.5
24
59 - 98 {6.0 - 10.0}
78 {8.0}
18
–
–
04
27
84 - 132 {8.5 - 13.5}
103 {10.5}
22
13 – - 16UN 16
20.7
05
32
128 - 186 {13.0 - 19.0}
157 {16.0}
24
1 - 14UNS
25.4
06
36
177 - 245 {18.0 - 25.0}
216 {22.0}
30
3 1 – - 12UNF 16
30.3
(10)
41
177 - 245 {18.0 - 25.0}
216 {22.0}
33
–
–
(12)
46
197 - 294 {20.0 - 30.0}
245 {25.0}
36
–
–
(14)
55
246 - 343 {25.0 - 35.0}
294 {30.0}
42
–
–
02
03
00-14
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS Copper wire Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Norminal number
Number of strands
Dia. of strands (mm2)
Cross section (mm2)
0.85
11
0.32
2
26
5
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification
1
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
—
BW
RW
YR
GW
LW
2 Color White & Red
—
Code
—
WB
White & Black Red & White Rellow & Red Green & White Blue & White BY
RB
YB
GR
LR
3
4
Auxiliary
Color White & Black
—
Code
—
WL
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR
Color White & Blue
—
Code
—
—
Color White & Green
—
—
Code
—
—
—
Color
—
—
—
WG
RY
Black & Red Red & Yellow RG
YG
GY
LY
Yellow & Green
Green & Yellow
Blue & Yellow
YL
GB
LB
5 Red & Green Yellow & Blue Green & Black Blue & Black RL
YW
GL
6 Red & Blue Yellow & White Green & Blue
n n
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line from A. (2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down from B. (3) Take the point where the two lines cross as C. This point C gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. B Millimeters to inches 1 mm = 0.03937 in
A
00-16
0
1
2
3
4
0 10 20 30 40
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 C 2.165 2.559 2.953 3.346 3.740
6
7
8
9
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
FOREWORD
CONVERSION TABLE
Millimeters to Inches 1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
0
Kilogram to Pound 1 kg = 2.2046 lb
0 0
0
1
2
3
4
5
6
7
8
9
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 1l = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
0
Liter to U.K. Gallon 1l = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
0
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb 1 kgm = 7.233 ft. lb
0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F
°C
°F
°C
°F
°C
°F
°C
°F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 0
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-21
FOREWORD
UNITS
UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
00-22
}.
01 GENERAL SPECIFICATION DRAWINGS ......................................................................................................................01- 2 SPECIFICATIONS ........................................................................................................................................01- 4 WEIGHT TABLE............................................................................................................................................01- 10 FUEL, COOLANT AND LUBRICANTS .........................................................................................................01- 14
PC750, 800-7
01-1
GENERAL
SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS BACKHOE SPECIFICATION DIMENSIONS
WORKING RANGES
01-2 (3)
PC750, 800-7
GENERAL
SPECIFICATION DRAWINGS
DIMENSIONS Item
Unit
PC750-7
PC750SE-7
PC750LC-7
PC800-7
PC800SE-7
A
Overall length
mm
14,305
13,030
14,305
13,895
13,030
B
Overall height
mm
4,660
4,615
4,660
4,850
4,615
C
Overall width
mm
4,210
4,210
4,310
4,210
4,210
D
Track shoe width
mm
710
710
810
710
710
E
Height of machine cab
mm
3,560
3,560
3,560
3,640
3,640
F
Tail swing radius
mm
4,300
4,300
4,300
4,300
4,300
G
Track overall length
mm
5,810
5,810
6,330
5,810
5,810
H
Length of track on ground
mm
4,500
4,500
5,020
4,500
4,500
Min. ground clearance
mm
840
840
840
840
840
Unit
PC750-7
PC750SE-7
PC750LC-7
PC800-7
PC800SE-7
WORKING RANGES Working range A
Max. digging reach
mm
13,740
12,265
13,740
13,660
12,265
B
Max. digging depth
mm
8,600
7,130
8,600
8,445
7,130
C
Max. digging height
mm
11,840
11,330
11,840
11,955
11,330
D
Max. vertical wall depth
mm
5,575
4,080
5,575
5,230
4,080
E
Max. dumping height
mm
8,145
7,525
8,145
8,235
7,525
F
Max. reach at ground level
mm
13,460
11,945
13,460
13,400
11,945
PC750, 800-7
01-3
GENERAL
SPECIFICATION DRAWINGS
LOADING SHOVEL SPECIFICATION DIMENSIONS
WORKING RANGES
01-3-1 (3)
PC750, 800-7
GENERAL
SPECIFICATION DRAWINGS
DIMENSIONS Item
Unit
PC750-7 (Loading shovel specification)
A
Overall length
mm
9,865
B
Overall height
mm
5,640
C
Overall width
mm
4,110
D
Track shoe width
mm
610
E
Height of machine cab
mm
3,560
F
Tail swing radius
mm
4,245
G
Track overall length
mm
5,810
H
Length of track on ground
mm
4,500
–
Min. ground clearance
mm
840
Unit
PC750-7 (Loading shovel specification)
WORKING RANGES Working range A
Max. digging reach
mm
10,305
B
Max. reach at ground level
mm
9,920
C
Max. digging height
mm
10,635
D
Max. digging depth
mm
3,535
E
Min. reach at ground level
mm
5,620
F
Min. swing radius of work equipment
mm
6,340
PC750, 800-7
01-3-2 (3)
GENERAL
SPECIFICATIONS
SPECIFICATIONS BACKHOE SPECIFICATION PC750-7
PC750SE-7
Serial Number
20001 and up
20001 and up
Bucket capacity
m3
3.1
4.0
Weight of machine
kg
72,500
73,300
Max. digging depth
mm
8,600
7,130
Max. vertical wall depth
mm
5,575
4,080
Max. digging reach
mm
13,740
12,265
Max. reach at ground level
mm
13,460
11,945
Max. digging height
mm
11,840
11,330
Max. dumping height
mm
8,145
7,525
kN {kg}
333.4 {34,000}
430.5 {43,900}
Swing speed
rpm
6.8
6.8
Swing max. slope angle
deg.
16
16
Travel speed
km/h
Low speed: 2.8
Low speed: 2.8
High speed: 4.2
High speed: 4.2
35
35
kPa {kg/cm }
101.01 {1.03}
102.97 {1.05}
Overall length
mm
14,305
13,030
Overall width
mm
4,335
4,335
Overall width of track
mm
3,490 (4,210)
3,490 (4,210)
Overall height
mm
4,660
4,615
Overall height to top of machine
mm
4,000
4,000
Ground clearance of upper struc-
mm
1,560
1,560
Min. ground clearance
mm
840
840
Tail swing radius
mm
4,300
4,245
Min. swing radius of work equip-
mm
6,060
5,645
mm
10,855
9,750
Length of track on ground
mm
4,500
4,500
Track gauge (when extended)
mm
2,780 (3,500)
2,780 (3,500)
Height of machine cab
mm
3,560
3,560
Working ranges Performance
Machine model
Max. digging force
Gradeability Ground pressure (standard double
deg. 2
grouser shoe width: 710 mm)
Dimensions
(when extended)
ture
ment Height of work equipment at min. swing radius
01-4 (3)
PC750, 800-7
GENERAL
SPECIFICATIONS
Machine model
PC750-7
PC750SE-7
Serial Number
20001 and up
20001 and up
mm l {cc}
SAA6D140E-3 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) 6 – 140 × 165 15.24 {15,240}
kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}
338/1,800 {454/1,800} 2,138/1,350 {218/1,350} 1,980 825 196 {146.4}
Model Type
Performance
Engine
No. of cylinders – bore × stroke Piston displacement Flywheel horsepower Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption
Starting motor Alternator Battery
24V, 11 kW 24V, 50A 12V, 170 Ah × 2 CWX-4 3 on each side
Track roller
8 on each side
Track shoe
Assembly-type double grouser, 47 on each side
Hydraulic motor Control valve Hydraulic pump
Carrier roller
Variable displacement piston type: HPV95+95, HPV95+95, gear type: SAR80+8
Type
Delivery Set pressure
l /min
Piston type: 490+490, gear type: 136+16
MPa {kg/cm2}
Piston type: 31.4 {320}, gear type: 2.9 {30}
Type × No.
4-spool + 5-spool type × 1
Control method
Hydraulic
Travel motor
Piston type (with brake valve, shaft brake): × 2 (MSF-340VP-EH11)
Swing motor
Piston type (with safety valve, shaft brake): × 2 (KMF125AB-5) Boom ( 1)
Hydraulic cylinder
Hydraulic system
Undercarriage
Radiator core type
Arm ( 1, PC750-7
2)
PC750SE-7
Bucket ( 1) PC750-7
PC750SE-7
Double-acting piston
Cylinder type Inside diameter of cylinder
mm
200
200
185
185
225
Outside diameter of piston rod
mm
140
140
120
120
160
Stroke
mm
1,950
2,250
1,610
1,610
1,420
Max. distance between pins
mm
4,880
5,525
3,990
3,990
3,910
Min. distance between pins
mm
2,930
3,275
2,380
2,380
2,490
Hydraulic tank Hydraulic filter Hydraulic cooler
1. With cushion on head side PC750, 800-7
Box-shaped, sealed with breather Tank return side Air cooled (J4)
2. With cushion on bottom side
01-5
GENERAL
Machine model
PC750LC-7
Serial Number
20001 and up
Bucket capacity
m3
3.1
Weight of machine
kg
78,100
Max. digging depth
mm
8,600
Max. vertical wall depth
mm
5,575
Max. digging reach
mm
13,740
Max. reach at ground level
mm
13,460
Max. digging height
mm
11,840
Max. dumping height
mm
8,145
kN {kg}
333.4 {34,000}
Swing speed
rpm
6.8
Swing max. slope angle
deg.
16
Travel speed
km/h
Low speed: 2.8
Working ranges Performance
SPECIFICATIONS
Max. digging force
High speed: 4.2 Gradeability Ground pressure (standard double
deg.
35
kPa {kg/cm }
86.3 {0.882}
Overall length
mm
14,305
Overall width
mm
4,455
Overall width of track
mm
4,310
Overall height
mm
4,660
Overall height to top of machine
mm
4,000
Ground clearance of upper
mm
1,560
Min. ground clearance
mm
840
Tail swing radius
mm
4,300
Min. swing radius of work equip-
mm
6,060
mm
10,855
Length of track on ground
mm
5,020
Track gauge (when extended)
mm
3,500
Height of machine cab
mm
3,560
2
grouser shoe width: 810 mm)
Dimensions
(when extended)
structure
ment Height of work equipment at min. swing radius
01-6
PC750, 800-7
GENERAL
SPECIFICATIONS
Machine model
PC750LC-7
Serial Number
20001 and up
Model
SAA6D140E-3
Type
4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled)
No. of cylinders – bore × stroke
Performance
Engine
Piston displacement
mm
6 – 140 × 165
l {cc}
15.24 {15,240}
Flywheel horsepower
kW/rpm {HP/rpm}
338/1,800 {454/1,800}
Max. torque
Nm/rpm {kgm/rpm}
2,138/1,350 {218/1,350}
Max. speed at no load
rpm
1,980
Min. speed at no load
rpm
825
Min. fuel consumption
g/kWh {g/HPh}
196 {146.4}
Starting motor
24V, 11 kW
Alternator
24V, 50A
Battery
12V, 170 Ah × 2 CWX-4
Track shoe
Assembly-type double grouser, 51 on each side
Hydraulic pump
9 on each side
Type
Control valve
3 on each side
Track roller
Type × No.
Hydraulic motor
Carrier roller
Travel motor
Piston type (with brake valve, shaft brake): × 2 (MSF-340VP-EH11)
Swing motor
Piston type (with safety valve, shaft brake): × 2 (KMF125AB-5)
Delivery Set pressure
Variable displacement piston type: HPV95+95, HPV95+95, gear type: SAR80+8 l /min
Piston type: 490+490, gear type: 136+16
MPa {kg/cm2}
Piston type: 31.4 {320}, gear type: 2.9 {30} 4-spool + 5-spool type × 1
Control method
Hydraulic
Boom ( 1) Hydraulic cylinder
Hydraulic system
Undercarriage
Radiator core type
Cylinder type
Arm ( 1,
2)
Bucket ( 1)
Double-acting piston
Double-acting piston
Double-acting piston
Inside diameter of cylinder
mm
200
200
180
Outside diameter of piston rod
mm
140
140
120
Stroke
mm
1,950
2,250
1,610
Max. distance between pins
mm
4,880
5,525
3,990
Min. distance between pins
mm
2,930
3,275
2,380
Hydraulic tank
Box-shaped, sealed with breather
Hydraulic filter
Tank return side
Hydraulic cooler
1. With cushion on head side PC750, 800-7
Air cooled (J4)
2. With cushion on bottom side
01-7
GENERAL
Machine model
PC800-7
PC800SE-7
Serial Number
40001 and up
40001 and up
Bucket capacity
m3
3.4
4.3
Weight of machine
kg
76,200
75,700
Max. digging depth
mm
8,445
7,130
Max. vertical wall depth
mm
5,230
4,080
Max. digging reach
mm
13,660
12,265
Max. reach at ground level
mm
13,400
11,945
Max. digging height
mm
11,955
11,330
Max. dumping height
mm
8,235
7,525
kN {kg}
362.8 {37,000}
430.5 {43,900}
Swing speed
rpm
6.8
6.8
Swing max. slope angle
deg.
16
16
Travel speed
km/h
Low speed: 2.8
Low speed: 2.8
High speed: 4.2
High speed: 4.2
35
35
kPa {kg/cm }
106.89 {1.09}
105.91 {1.08}
Overall length
mm
13,895
13,030
Overall width
mm
4,335
4,335
Overall width of track
mm
3,490 (4,210)
3,490 (4,210)
Overall height
mm
4,850
4,615
Overall height to top of machine
mm
4,000
4,000
Ground clearance of upper
mm
1,560
1,560
Min. ground clearance
mm
840
840
Tail swing radius
mm
4,300
4,300
Min. swing radius of work equip-
mm
5,985
5,645
mm
10,430
9,750
Length of track on ground
mm
4,500
4,500
Track gauge (when extended)
mm
2,780 {3,500}
2,780 {3,500}
Height of machine cab
mm
3,640
3,640
Working ranges Performance
SPECIFICATIONS
Max. digging force
Gradeability Ground pressure (standard double
deg. 2
grouser shoe width: 710 mm)
Dimensions
(when extended)
structure
ment Height of work equipment at min. swing radius
01-8
PC750, 800-7
GENERAL
SPECIFICATIONS
Machine model
PC800-7
PC800SE-7
Serial Number
40001 and up
40001 and up
mm l {cc}
SAA6D140E-3 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) 6 – 140 × 165 15.24 {15,240}
kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}
338/1,800 {454/1,800} 2,138/1,350 {218/1,350} 1,980 825 196 {146.4}
Model Type
Performance
Engine
No. of cylinders – bore × stroke Piston displacement Flywheel horsepower Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption
Starting motor Alternator Battery
24V, 11 kW 24V, 50A 12V, 170 Ah × 2 CWX-4 3 on each side
Track roller
8 on each side
Track shoe
Assembly-type double grouser, 47 on each side
Hydraulic motor Control valve Hydraulic pump
Carrier roller
Type Delivery Set pressure
Variable displacement piston type: HPV95+95, HPV95+95, gear type: SAR80+8 l /min
Piston type: 490+490, gear type: 136+16
MPa {kg/cm2}
Piston type: 31.4 {320}, gear type: 2.9 {30}
Type × No.
4-spool + 5-spool type × 1
Control method
Hydraulic
Travel motor
Piston type (with brake valve, shaft brake): × 2 (MSF-340VP-EH11)
Swing motor
Piston type (with safety valve, shaft brake): × 2 (KMF125AB-5) Boom ( 1)
Hydraulic cylinder
Hydraulic system
Undercarriage
Radiator core type
Arm ( 1, 2)
Bucket ( 1) PC800-7
PC800SE-7
Double-acting piston
Cylinder type Inside diameter of cylinder
mm
200
185
185
225
Outside diameter of piston rod
mm
140
120
120
160
Stroke
mm
1,950
1,610
1,820
1,420
Max. distance between pins
mm
4,880
3,990
4,410
3,910
Min. distance between pins
mm
2,930
2,380
2,590
2,490
Hydraulic tank Hydraulic filter Hydraulic cooler
1. With cushion on head side
PC750, 800-7
Box-shaped, sealed with breather Tank return side Air cooled (J4)
2. With cushion on bottom side
01-9
GENERAL
SPECIFICATIONS
LOADING SHOVEL SPECIFICATION PC750-7
Serial Number
20001 and up
Bucket capacity
m3
4.5
Weight of machine
kg
76,000
Max. digging depth
mm
3,535
Max. vertical wall depth
mm
—
Max. digging reach
mm
10,305
Max. reach at ground level
mm
9,920
Max. digging height
mm
10,635
Max. dumping height
mm
7,180
kN {kg}
476.3 {48,600}
Swing speed
rpm
6.8
Swing max. slope angle
deg.
16
Travel speed
km/h
Low speed: 2.8
Working ranges Performance
Machine model
Max. digging force
High speed: 4.2 Gradeability Ground pressure (standard double
deg.
35
kPa {kg/cm }
124 {1.26}
Overall length
mm
9,865
Overall width
mm
4,335
Overall width of track (when extended)
mm
3,390 (4,110)
Overall height
mm
5,640
Overall height to top of machine
mm
4,000
Ground clearance of upper structure
mm
1,560
Min. ground clearance
mm
840
Tail swing radius
mm
4,300
Min. swing radius of work equipment
mm
6,340
Height of work equipment at
mm
7,090
Length of track on ground
mm
4,500
Track gauge (when extended)
mm
2,780 (3,500)
Height of machine cab
mm
3,560
2
Dimensions
grouser shoe width: 610 mm)
min. swing radius
01-9-1 (3)
PC750, 800-7
GENERAL
SPECIFICATIONS
Machine model
PC750-7
Serial Number
20001 and up
Model Type
Performance
Engine
No. of cylinders – bore × stroke Piston displacement Flywheel horsepower Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption
mm l {cc}
SAA6D140E-3 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (air cooled) 6 – 140 × 165 15.24 {15,240}
kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}
338/1,800 {460/1,800} 2,138/1,350 {218/1,350} 1,980 825 196 {144}
Starting motor Alternator Battery
24 V, 11 kW 24 V, 50 A 12 V, 170 Ah × 2 CWX-4 3 on each side
Track roller
8 on each side
Track shoe
Assembly-type double grouser, 47 on each side
Hydraulic motor Control valve Hydraulic pump
Carrier roller
Variable displacement piston type: HPV95+95, HPV95+95, gear type: SAR80+8
Type
Delivery Set pressure
l /min
Piston type: 490+490, gear type: 136+16
MPa {kg/cm2}
Piston type: 31.4 {320}, gear type: 2.9 {30}
Type × No.
4-spool + 5-spool type × 1
Control method
Hydraulic
Travel motor
Piston type (with brake valve, shaft brake): × 2 (MSF-340VP)
Swing motor
Piston type (with safety valve, shaft brake): × 2 (KMF125AB-5) Boom
Hydraulic cylinder
Hydraulic system
Undercarriage
Radiator core type
Arm
Bucket
Bottom dump
Double-acting piston
Cylinder type Inside diameter of cylinder
mm
200
225
185
140
Outside diameter of piston rod
mm
140
160
130
90
Stroke
mm
1,490
1,530
1,550
335
Max. distance between pins
mm
4,340
4,130
4,275
1,235
Min. distance between pins
mm
2,850
2,600
2,725
900
Hydraulic tank Hydraulic filter Hydraulic cooler
PC750, 800-7
Box-shaped, sealed with breather Tank return side Air cooled (J4)
01-9-2 (3)
GENERAL
WEIGHT TABLE
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components Unit: kg Machine model
PC750-7
PC750SE-7
PC750LC-7
Serial Number
20001 and up
20001 and up
20001 and up
Engine assembly
2,554
2,554
2,554
• Engine
1,720
1,720
1,720
• PTO (incl. lubricating piping)
500
500
500
• No. 1 pump
165
165
165
• No. 2 pump
150
150
150
• Control, PTO lubrication pump
19
19
19
Radiator assembly
260
260
260
Oil cooler assembly
200
200
200
Hydraulic tank (excl. hydraulic oil)
664
664
664
6,960
6,960
6,960
293
293
293
Swing machinery
490 × 2
490 × 2
490 × 2
Swing motor assembly
57 × 2
57 × 2
57 × 2
Travel motor assembly
130 × 2
130 × 2
130 × 2
L.H. 5-spool control valve
245
245
245
R.H. 4-spool control valve
240
240
240
Center swivel joint
69
69
69
Counterweight
9,800
9,800
9,800
Track frame assembly
19,845
19,854
20,626
• Center frame
5,550
5,550
5,550
• Track frame
2,630 × 2
2,630 × 2
2,880 × 2
• Carrier roller
51.8 × 6
51.8 × 6
51.8 × 6
• Track roller
136 × 16
136 × 16
136 × 18
• Idler cushion assembly
782 × 2
782 × 2
782 × 2
• Idler
450 × 2
450 × 2
450 × 2
1,344 × 2
1,344 × 2
1,344 × 2
1,405
1,405
1,405
Revolving frame (incl. left and right decks) Operator's cab
• Final drive assembly • Swing circle assembly
01-10
PC750, 800-7
GENERAL
WEIGHT TABLE
Unit: kg Machine model
PC750-7
PC750SE-7
PC750LC-7
Serial Number
20001 and up
20001 and up
20001 and up
• Narrow shoe (610 mm)
7,550
7,550
—
• Standard shoe (710 mm)
8,350
8,350
—
• Wide shoe (810 mm)
8,880
8,880
10,020
• Wide shoe (910 mm)
9,520
9,520
—
• Wide shoe (1,010 mm)
10,160
10,160
11,520
• Wide shoe (1,110 mm)
—
—
12,270
Boom assembly (excl. piping)
7,420
6,850
7,420
Arm assembly (excl. piping)
2,690
3,160
3,035
Bucket assembly (excl. piping)
2,960
3,435
2,960
790 × 2
790 × 2
790 × 2
Arm cylinder assembly
881
497 × 2
881
Bucket cylinder assembly
506
933
506
Boom foot pin
45.2 × 2
45.2 × 2
45.2 × 2
Boom cylinder foot pin
33.8 × 2
33.8 × 2
33.8 × 2
Boom cylinder top pin
32.5 × 2
32.5 × 2
32.5 × 2
Boom-arm connecting pin
105
105
105
Arm cylinder foot pin
53.6
24 × 2
53.6
Arm cylinder top pin
30
24 × 2
30
Link-arm connecting pin
56.1
56.1
56.1
Link-bucket connecting pin
62.2
62.2
62.2
Bucket cylinder top pin
49.3
84.5
49.3
Bucket cylinder foot pin
25.3
43.8
25.3
Arm-bucket connecting pin
91.4
91.4
91.4
Link assembly
410.4
445
410.4
Track shoe assembly
Boom cylinder assembly
PC750, 800-7
01-11
GENERAL
WEIGHT TABLE
Unit: kg Machine model
PC800-7
PC800SE-7
Serial Number
40001 and up
40001 and up
Engine assembly
2,554
2,554
• Engine
1,720
1,720
• PTO (incl. lubricating piping)
500
500
• No. 1 pump
165
165
• No. 2 pump
150
150
• Control, PTO lubrication pump
19
19
Radiator assembly
260
260
Oil cooler assembly
200
200
Hydraulic tank (excl. hydraulic oil)
664
664
6,960
6,960
293
293
Swing machinery
490 × 2
490 × 2
Swing motor assembly
57 × 2
57 × 2
Travel motor assembly
130 × 2
130 × 2
L.H. 5-spool control valve
245
245
R.H. 4-spool control valve
240
240
Center swivel joint
69
69
Counterweight
12,000
12,000
Track frame assembly
19,854
19,854
• Center frame
5,550
5,550
• Track frame
2,630 × 2
2,630 × 2
• Carrier roller
51.8 × 6
51.8 × 6
• Track roller
136 × 16
136 × 16
• Idler cushion assembly
782 × 2
782 × 2
• Idler
450 × 2
450 × 2
1,344 × 2
1,344 × 2
1,405
1,405
Revolving frame (incl. left and right decks) Operator's cab
• Final drive assembly • Swing circle assembly
01-12
PC750, 800-7
GENERAL
WEIGHT TABLE
Unit: kg Machine model
PC800-7
PC800SE-7
Serial Number
40001 and up
40001 and up
• Narrow shoe (610 mm)
7,550
7,550
• Standard shoe (710 mm)
8,350
8,350
• Wide shoe (810 mm)
—
—
• Wide shoe (910 mm)
—
—
• Wide shoe (1,010 mm)
—
—
• Wide shoe (1,110 mm)
—
—
Boom assembly (excl. piping)
7,660
6,850
Arm assembly (excl. piping)
3,135
3,160
Bucket assembly (excl. piping)
3,540
3,840
Boom cylinder assembly
790 × 2
790 × 2
Arm cylinder assembly
497 × 2
497 × 2
545
933
Boom foot pin
45.2 × 2
45.2 × 2
Boom cylinder foot pin
33.8 × 2
33.8 × 2
Boom cylinder top pin
32.5 × 2
32.5 × 2
105
105
Arm cylinder foot pin
24 × 2
24 × 2
Arm cylinder top pin
24 × 2
24 × 2
Link-arm connecting pin
56.1
56.1
Link-bucket connecting pin
62.2
62.2
Bucket cylinder top pin
49.3
84.5
Bucket cylinder foot pin
25.3
43.8
Arm-bucket connecting pin
91.4
91.4
Link assembly
479
445
Track shoe assembly
Bucket cylinder assembly
Boom-arm connecting pin
PC750, 800-7
01-13
GENERAL
FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS
01-14 (1)
PC750, 800-7
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PTO ......................................................... 10- 2 PTO LUBRICATION SYSTEM................. 10- 3 POWER TRAIN ....................................... 10- 4 SWING MACHINERY .............................. 10- 6 SWING CIRCLE ...................................... 10- 8 FINAL DRIVE .......................................... 10- 10 SPROCKET ............................................. 10-11-1 TRACK FRAME AND RECOIL SPRING . 10- 12 IDLER ...................................................... 10- 14 CARRIER ROLLER ................................. 10- 16 TRACK ROLLER ..................................... 10- 17 TRACK SHOE ......................................... 10- 18 MOTOR GREASE PUMP ........................ 10- 23 HYDRAULIC TANK.................................. 10- 24 HYDRAULIC PUMP ................................ 10- 26 RETURN OIL FILTER.............................. 10- 56 LINE OIL FILTER..................................... 10- 57 PILOT OIL FILTER .................................. 10- 57 DRAIN OIL FILTER.................................. 10- 58 L.H. 5-SPOOL CONTROL VALVE........... 10- 60
PC750, 800-7
R.H. 4-SPOOL CONTROL VALVE ...........10- 66 STRAIGHT-TRAVEL VALVE ....................10- 72 SWING MOTOR.......................................10- 75 CENTER SWIVEL JOINT.........................10- 80 TRAVEL MOTOR .....................................10- 81 PPC CONTROL RELIEF VALVE..............10- 91 PPC ACCUMULATOR .............................10- 92 VALVE CONTROL....................................10- 93 WORK EQUIPMENT, SWING PPC VALVE ...........................10- 94 TRAVEL PPC VALVE ...............................10-100 SOLENOID VALVE...................................10-104 HYDRAULIC CYLINDER .........................10- 110 WORK EQUIPMENT................................10- 114 DIMENSIONS OF WORK EQUIPMENT ..10- 118 AIR CONDITIONER .................................10-122 ENGINE CONTROL .................................10-123 MACHINE CONTROL SYSTEM ..............10-129 MONITOR SYSTEM.................................10-158 SENSORS................................................10-173
10-1 (3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PTO
PTO
1. 2. 3. 4. 5. 6. 7.
PTO case Driven gear (No. of teeth: 56) Main shaft Hub Connection plate Driven gear (No. of teeth: 42) Breather
Specifications Lubricating oil: 13.5 l (EO30-CD) 56 Reduction ratio: HPV95 + 95 shaft = 42 = 1.333 56 HPV95 + 95 shaft = 42 = 1.333 SAR80 + 8 shaft = 1.000
a. Center of crankshaft (SRA80 + 8) b. Center of HPV95 + 95 shaft c. Center of HPV95 + 95 shaft
Unit: mm No.
Check item
8
Backlash of gear pump spline (for SAR80 + 8)
9 10
10-2
Criteria
Remedy
Standard size
Repair limit
0.273 – 0.374
—
Backlash between drive gear and driven gear (for SAL63 + 8)
0.2 – 0.74
—
Backlash of main pump spline (for HPV95 + 95)
0.07 – 0.18
—
Adjust
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PTO LUBRICATION SYSTEM
PTO LUBRICATION SYSTEM Hydraulic circuit diagram
Hydraulic piping diagram
1. 2. 3. 4. 5.
PTO case Divider block Lubricating pipe Control, PTO lubricating pump (SAR80 + 8) Oil filter
PC750, 800-7
Outline The PTO uses the SAR8 of control and PTO lubricating pump (4). The lubricating oil inside PTO case (1) passes through oil filter (5), is sent to top divider block (2), and is then divided to various parts of the PTO to lubricate and cool the gears.
10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
POWER TRAIN
10-4
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Idler Center swivel joint Swing motor (KMF125AB-5) L.H. 5-spool control valve R.H. 4-spool control valve Final drive, sprocket Travel motor Engine PTO No. 1 pump (HPV95 + 95)
PC750, 800-7
11. 12. 13. 14. 15. 16.
POWER TRAIN
No. 2 pump (HPV95 + 95) Control, PTO lubricating pump Swing brake solenoid valve Travel speed solenoid valve Swing machinery Swing circle
A. L.H. 5-spool control valve B. Swing brake solenoid valve
10-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MACHINERY
SWING MACHINERY
10-6
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MACHINERY
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Swing pinion (No. of teeth: 13) Cover Case Coupling No. 2 planetary gear (No. of teeth: 38) Ring gear (No. of teeth: 97) No. 1 planetary gear (No. of teeth: 38) Cover Dipstick Swing motor No. 1 sun gear (No. of teeth: 20) No. 1 planetary carrier No. 2 sun gear (No. of teeth: 19) No. 2 planetary carrier Drain plug
Specification Reduction ratio: 20 + 97 × 19 + 97 = 35.716 20 19 Unit: mm No.
Check item
16
Backlash between swing motor shaft and No. 1 sun gear
17
Criteria
Remedy
Standard clearance
Clearance limit
0.19 – 0.29
—
Backlash between No. 1 sun gear and No. 1 planet gear
0.19 – 0.51
0.90
18
Backlash between No. 1 planet gear and ring gear
0.24 – 0.70
0.90
19
Backlash between No. 2 planet carrier and coupling
0.06 – 0.24
—
20
Backlash between No. 1 planet carrier and No. 2 sun gear
0.38 – 0.78
1.10
21
Backlash between No. 2 sun gear and No. 2 planet gear
0.17 – 0.52
1.00
22
Backlash between No. 2 planet gear and ring gear
0.21 – 0.64
1.10
23
Backlash between coupling and swing pinion
0.08 – 0.25
—
24
Backlash between swing pinion and swing circle
0 – 1.5
2.00
0.06 – 0.86
—
Standard size
Repair limit
25
Clearance between plate and coupling
26
Wear of swing pinion oil seal contact surface
PC750, 800-7
Replace
0
150 –0.100
—
Repair hard chrome plating or replace
10-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING CIRCLE
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 112) 2. Ball 3. Swing circle outer race
Specifications 112 = –8.615 13 Amount of grease: 65 l (G2-LI) Reduction ratio: –
a. Inner race soft zone "S" position b. Outer race soft zone "plug" position
Unit: mm No.
Check item
4
Clearance of bearing in axial direction (when mounted on machine)
10-8
Criteria
Remedy
Standard clearance
Repair limit
0.5 – 1.6
3.2
Replace
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FINAL DRIVE
FINAL DRIVE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Level plug Drain plug Cover No. 2 planetary carrier No. 2 sun gear (No. of teeth: 19) Drive gear (No. of teeth: 19) No. 1 planetary carrier No. 2 planet gear (No. of teeth: 24) Hub Sprocket Floating seal Case Coupling No. 1 sun gear (No. of teeth: 13) Travel motor Idler gear (No. of teeth: 27) No. 1 ring gear (No. of teeth: 68) No. 1 planet gear (No. of teeth: 24) Driven gear (No. of teeth: 69) No. 2 ring gear (No. of teeth: 69)
10-10
Specifications Reduction ratio: – ( 13 + 68 ) × ( 19 + 69 ) × 69 13 19 19 = –104.802
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FINAL DRIVE
Unit: mm No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.08 – 0.27
—
Backlash between drive gear and No. 1 planetary carrier
0.21 – 0.57
—
23
Backlash between No. 2 sun gear and No. 1 planetary carrier
0.24 – 0.91
—
24
Backlash between No. 2 sun gear and No. 2 planet gear
0.23 – 0.68
—
25
Backlash between No. 2 planetary carrier and No. 2 ring gear
0.28 – 0.87
—
26
Backlash between coupling and drive gear
0.38 – 0.72
—
27
Backlash between No. 1 ring gear and case
0.08 – 0.26
—
28
Backlash between No. 1 sun gear and travel motor coupling
0.07 – 0.18
—
29
Backlash between No. 1 sun gear and idler gear
0.15 – 0.62
—
30
Backlash between No. 1 ring gear and idler gear
0.19 – 0.62
—
31
Backlash between driven gear and No. 1 planet gear
0.19 – 0.62
—
32
Wear of sprocket tooth shape
21
Backlash between No. 2 planetary carrier and case
22
33
Sprocket tooth width
PC750, 800-7
Replace
Repair limit: 6 Standard size
Repair limit
114
108
Rebuild or replace
10-11
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SPROCKET
SPROCKET
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
403.6
391.6
Thickness of tooth root
28.4
22.4
3
Width of tooth
114
108
4
Wear of tooth shape
1
Wear of tooth tip
2
10-11-1 (3)
Build-up welding or replace
Repair limit: 6 (measure with sprocket tooth shape)
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SPROCKET
SPROCKET TOOTH SHAPE OF REAL DIMENSION
a The above drawing is reduced to 50%. Enlarge it to 200% to return it to the full scale and make a copy on an OHP sheet.
PC750, 800-7
10-11-2 (3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK FRAME AND RECOIL SPRING
TRACK FRAME AND RECOIL SPRING a The diagram shows the PC750-7.
1. 2. 3. 4. 5. 6. 7. 8. 9.
Idler Track frame Carrier roller Center frame Final drive Track roller Track shoe Idler cushion Front guard
10-12
•
The dimensions and number of track rollers may differ according to the model, but the basic structure is the same.
•
No. of track rollers Model
No. of rollers (each side)
PC750, 750SE-7 PC800, 800SE-7
8
PC750LC-7
9
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK FRAME AND RECOIL SPRING
Unit: mm
Standard shoe Model Item Shoe width (double shoe) Link pitch No. of shoes (each side)
PC750-7
PC750SE-7
PC750LC-7
PC800-7
PC800SE-7
710
710
810
710
710
260.6
260.6
260.6
260.6
260.6
47
47
51
47
47
Unit: mm No.
10
11
Check item
Top-to-bottom width of idler guide
Left-to-right width of idler guide
Criteria
Remedy
Standard size
Tolerance
Repair limit
Track frame
185
+3 185 –2
190
Idler support
180
185±0.5
175
Replace
Track frame
345
345 –2
355
Rebuild or replace
Idler support
340
—
332
+3
Standard size 12
Recoil spring
PC750, 800-7
Rebuild or replace
Repair limit
Free length × OD
Installation length
Installation load
Free length
Installation load
1,553 × 308
1,290
489.8 kN {49,986 kg}
—
392 kN {40,000 kg}
Replace
10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
IDLER
IDLER
10-14
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
IDLER
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
875
—
Outside diameter of tread surface
830
818
3
Depth of tread
22.5
28.5
4
Overall width
266
—
5
Width of tread
69.5
—
1
Outside diameter of protruding part
2
6
Clearance between shaft and bushing
Standard size 110
7
Interference between idler and bushing
Standard size 120
PC750, 800-7
Tolerance
Rebuild or replace
Shaft
Hole
Standard clearance
Clearance limit
–0.120 –0.207
+0.361 +0.281
0.401 – 0.568
1.5
Tolerance Shaft
Hole
+0.087 +0.037
–0.036 –0.136
Standard Interference interference limit 0.073 – 0.223
Replace bushing
—
10-15
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CARRIER ROLLER
CARRIER ROLLER
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
194
—
Outside diameter of tread
175
155
3
Width of tread
68
—
4
Thickness of tread
57.6
47.6
5
Width of flange
17
—
1
Outside diameter of flange
2
6
Interference between bearing and support
7
Interference between bearing and shaft
8
Play of roller in axial direction
10-16
Standard size
Tolerance
Rebuild or replace
Standard Interference interference limit
Shaft
Hole
110
0 –0.015
0 –0.035
–0.015 – 0.035
—
60
+0.039 +0.020
0 –0.015
0.020 – 0.054
—
Standard clearance
Clearance limit
0 – 0.301
0.43
Replace
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK ROLLER
TRACK ROLLER
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
298
—
Outside diameter of tread surface
255
243
3
Thickness of tread
73.7
67.7
4
Overall width
328
—
5
Inside width
126
—
6
Width of tread
72
—
7
Width of flange
29
—
1
Outside diameter of flange
2
8
Clearance between shaft and bushing
Standard size 100
9
Interference between roller and bushing
Standard size 107.6
PC750, 800-7
Tolerance
Rebuild or replace
Shaft
Hole
Standard clearance
Clearance limit
–0.140 –0.207
+0.375 +0.235
0.375 – 0.582
1.5
Tolerance Shaft
Hole
+0.087 +0.037
+0.020 –0.015
Standard Interference interference limit 0.017 – 0.102
Replace bushing
—
10-17
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK SHOE
TRACK SHOE (1/2) TRACK SHOE
a P portion shows the link of bushing press-fitting end.
10-18
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK SHOE
Unit: mm No.
Check item
Criteria
Remedy
Standard size 1
2
Link pitch
260.6
Bushing outside diameter
Link height
4
Thickness of link metal (bushing press-fitting portion)
5 6
Standard size
Normal load
Impact load
82.5
—
Standard size
Repair limit
156
143
39.3
26.3 234.95
Shoe bolt pitch
Repair or replace
Replace
76.2
8 Link
10
Inside width
133.6
Overall width
73
Tread width
65
11
Protrusion of pin
4.5
12
Protrusion of regular bushing
10.8
13
Overall length of pin
320.4
14
Overall length of bushing
225.8
15
Thickness of bushing metal
15.75
16
Thickness of spacer
12.45
17 18
Reverse or replace
184.2
7
9
263.6 (Heavy-duty areas) 265.6 (Standard areas) When turned
87.5 3
Repair limit
Press-fitting force
19
Bushing
130 – 217 kN {13.3 – 22.1 ton}
Regular pin
312 – 350 kN {31.8 – 35.7 ton}
Master pin
249 – 294 kN {25.9 – 30 ton}
Repair or replace
Adjust or replace
—
: Dry type track link
PC750, 800-7
10-19 (1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK SHOE
(2/2)
a P portion shows the link of bushing press-fitting end.
10-20
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK SHOE
Unit: mm No.
Check item a. Regular link
20
Shoe bolt b. Master link
Criteria Tightening torque (Nm {kgm})
Additinal tightening angle (deg.)
784±78 {80±8}
120±10
Tightening torque (Nm {kgm})
Additinal tightening angle (deg.)
Lower limit torque (Nm {kgm})
—
—
—
No. of shoes (each side)
21
22
23
Interference between bushing and link
Interference between regular pin and link
Clearance between regular pin and bushing
PC750, 800-7: 47, PC750LC-7: 51 Standard size
Interference between master pin and link
25
Standard interference
Hole
87.5
+0.472 +0.372
+0.087 0
0.285 – 0.472
55.2
+0.596 +0.496
+0.074 0
0.422 – 0.596
Standard size
Standard size 55.2
Clearance between master pin and bushing
Tolerance
Standard size 56
Tolerance Shaft
Hole
+0.05 –0.05
+1.286 +0.786 Tolerance
Shaft
Hole
+0.442 +0.412
+0.074 0 Tolerance
Shaft
Hole
+0.296 +0.196
+1.036 +0.536
Retighten
—
Shaft
56
24
Remedy
Standard clearance 0.736 – 1.236
Adjust or replace
Standard interference 0.338 – 0.442 Standard clearance 0.24 – 0.84
: Dry type track link
PC750, 800-7
10-21
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK SHOE
DOUBLE SHOE
Unit: mm No.
Check item
Criteria Standard size
Repair limit
50
25
1
Height
2
Height
50
3
Thickness
20
4 5 6 7
Length at bottom
Length at top
10-22
Remedy
39
Rebuild or replace
— 30 30
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MOTOR GREASE PUMP
MOTOR GREASE PUMP
1. 2. 3. 4. 5. 6. 7. 8.
Motor grease pump unit Valve Cover Air chamber Follower plate Grease chamber Grease tank Wing nut
PC750, 800-7
Function • The pump unit is divided into air chamber (4) and grease chamber (6). As the grease level in grease chamber (6) lowers, follower plate (5) is pulled down to push down the grease sticking to the rim of grease chamber (6).
10-23
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC TANK
HYDRAULIC TANK
1. 2. 3. 4. 5. 6. 7. 8. 9.
Hydraulic tank Strainer Oil filler cap Pressure valve Suction strainer Sight gauge Drain valve Hydraulic oil level sensor Hydraulic oil temperature sensor
10-24
Specifications Tank capacity : 729 l Amount of oil inside tank : 482 l (at H level) Pressure valve Relief cracking pressure : 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2} Suction cracking pressure: 0 – 0.49 kPa {0 – 0.005 kg/cm2}
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
HYDRAULIC PUMP NO. 1 PUMP ASSEMBLY HPV95 + 95
1. 2. 3. 4. 5. 6. 7.
Front servo valve Front CO, NC valve Rear servo valve Rear CO, NC valve TVC valve Rear pump Front pump
10-26
PA1 : PA2 : Ps : Pt : Pd :
Discharge port Discharge port Suction port Jet sensor upstream pressure IN port Jet sensor downstream pressure IN port Psv : Servo basic pressure supply port
Pecn : CO, NC valve output pressure detection port Pd11 : Drain port Pd21 : Drain port PCF : CO cancelling pressure pilot port PCR : CO cancelling pressure pilot port
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
1. No. 1 main pump
Psv1 : Servo valve basic pressure port Psv2 : Servo valve basic pressure port Psv1A : Servo piston output port
PC750, 800-7
Psv2A : Servo piston output port Psv1B : Servo valve output port Psv2B : Servo valve output port
10-27
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5.
Front shaft Front cradle Front case Rocker cam Piston
10-28
6. 7. 8. 9. 10.
Cylinder block Valve plate Front end cap Impeller Coupling
HYDRAULIC PUMP
11. 12. 13. 14. 15.
Rear end cap Rear case Rear cradle Rear shaft Servo piston
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
2. No. 1 pump front servo assembly
1. CO, NC valve assembly 2. Servo valve assembly PA1 : Main pump pressure IN port Pe2 : TVC valve output pressure front, rear interconnection port Psv : Servo basic pressure IN port
PC750, 800-7
Pac : Pc : : Pt Pd : Pecn : Pdr :
Servo actuator port CO selector pilot port Jet sensor upstream pressure IN port Jet sensor downstream pressure IN port CO, NC valve output pressure detection port Servo valve drain OUT port
10-29
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
3. No. 1 pump rear servo assembly
1. 2. 3. 4.
TVC valve CO, NC valve assembly Connector Servo valve assembly
PA1 : Main pump pressure IN port PA2 : Main pump pressure IN port Psv : Servo basic pressure IN port
10-30
Pac : Servo actuator port Pc : CO selector pilot port Pt : Jet sensor upstream pressure IN port Pd : Jet sensor downstream pressure front, rear interconnection port Pe : TVC valve output pressure front, rear interconnection port Pdr : Servo valve drain OUT port
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
4. Servo valve • No. 1 pump front servo valve
PA2 : Main pump pressure OUT port Pdr : CO, NC valve drain port Pecn : CO, NC valve output pressure IN port
PC750, 800-7
10-31
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
•
HYDRAULIC PUMP
No. 1 pump rear servo valve
PA1 PA2 Pdr Psv2 Pecn
: Main pump pressure OUT port : Main pump pressure OUT port : CO, NC valve drain port : Servo basic pressure OUT port : CO, NC valve output pressure IN port
10-32
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6.
Locknut Cover Plug Spring Valve body Arm
7. 8. 9. 10. 11. 12.
Pin Control piston Locknut Plug Locknut Cover
HYDRAULIC PUMP
13. 14. 15. 16. 17. 18.
Sleeve Guide spool Spring Plug Cover Locknut
Function Discharge amounts Q1 and Q2 of main pumps PA1 and PA2 are controlled individually by the respective servo valves. The relationship between pump discharge amount Q and input signal Pecn to the servo valve is as shown in the graph on the right. Q varies in proportion to Pecn.
PC750, 800-7
10-33
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
Operation 1) Operation in direction of increase of pump discharge amount (max. angle)
•
•
•
The control pump pressure Psv is taken to port a. Signal pressure Pecn from the NC valve is taken from port b to chamber c. When signal pressure Pecn rises, control piston (8) is pushed to the left by the hydraulic pressure in chamber c, and stops at a point where it balances the pressure of springs (4) and (4A). At the same time, arm (6) uses servo piston (19) as a fulcrum and sways to the left in the same way as control piston (8). This moves guide spool (13) to the left. When guide spool (13) moves, port a and port d are closed and port d is connected to drain chamber e. As a result, servo piston chamber f is also interconnected with chamber e through port g and port d.
10-34
•
At the same time, port a is interconnected with port h, so the oil flows through port i to servo piston chamber j, pushes servo piston (19) to the left, increases the swash plate angle in the main piston pump and increases the pump discharge amount. When servo piston (19) moves, arm (6) rotates clockwise with its center at pin (7). Guide spool (13) is moved to the right and closes port a, port d and port h, so the discharge increases by an amount that matches signal pressure Pecn.
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
2) Operation in direction of decrease of pump discharge amount (min. angle)
•
•
When signal pressure Pecn goes down, control piston (8) moves to the right and stops at a point where the hydraulic pressure in chamber c balances the pressure of springs (4) and (4A). At the same time, arm (6) uses servo piston (19) as a fulcrum and sways to the right in the same way as control piston (8). This moves guide spool (13) to the right. When guide spool (13) moves, port a and port h are closed and port h is connected to drain chamber e. As a result, servo piston chamber j is also interconnected with chamber e through port i and port h. At the same time, port a is interconnected with port d, so the oil flows through port g to servo piston chamber f, pushes servo piston (19) to the right, decreases the swash plate angle in the main piston pump and decreases the pump discharge amount.
PC750, 800-7
•
When servo piston (19) moves, arm (6) rotates counterclockwise with its center at pin (7). Guide spool (13) is moved to the left and closes port a, port d and port h, so the discharge decreases by an amount that matches signal pressure Pecn.
10-35
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
5. TVC valve
Psv : Servo basic pressure IN port PA1 : Main pump pressure IN port PA2 : Main pump pressure IN port Pd : TVC valve drain OUT port Pe : TVC valve output pressure OUT port
10-36
1. 2. 3. 4.
Spring Spool Piston Piston
5. 6. 7. 8.
Sleeve Piston Body Solenoid
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
Operation and function of TVC valve 1) When command current value from controller is small in A and E mode
Function • When the power mode is at A mode or E mode, the pump discharge amount is controlled to the optimum amount by the command current sent from the controller in accordance with the variation in the engine speed. • When the pump prolix switch is ON, the pump discharge amount is controlled according to the pump discharge pressure (load) by hydraulic sensing which follows a constant pump absorption torque. a For details, see MACHINE CONTROL SYSTEM.
PC750, 800-7
Operation • The command current sent from the controller actuates solenoid push pin (9) and spool (2) moves. When this happens, the piston stops at a point where it balances the total of the force of spring (1), the force of push pin (9), and the force of TVC output pressure Pe acting on piston (3). The command current at this point is small, so spool (2) is balanced at the bottom. As a result, port a and port b are almost completely open, so the pressure oil from the control pump is almost all output as TVC output pressure Pe. In thi s way, th e p ump di s cha r ge amou nt becomes the maximum.
10-37
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
2) When command current value from controller is large in A and E mode
Operation • The command current sent from the controller actuates solenoid push pin (9) and spool (2) moves. When this happens, the piston stops at a point where it balances the force of spring (1). The command current at this point is large, so spool (2) is balanced at the top. As a result, the flow of oil from the control pump at port a and port b is throttled. At the same time, the area of the opening at port b and port c (drain port) becomes larger. In this way, TVC output pressure Pe goes down, and the pump discharge amount decreases.
10-38
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
3) When pump load is small in pump prolix switch ON
•
•
•
If the pump prolix switch is turned ON, solenoid push pin (9) is pushed up to heighten the set pressure of spring (1), and then spring (1) is kept under this condition. As a result, the pump absorption torque becomes constant, so TVC output pressure Pe (= pump discharge amount) is controlled by the pump discharge pressure. Main pump discharge pressures PA1 and PA2 are low, so spool (2) is pushed down fully by spring (1). As a result, control pump discharge pressure Psv and TVC valve output pressure Pe are equal. At this point, TVC valve output pressure Pe becomes the maximum, and the main pump discharge amount is also the maximum.
PC750, 800-7
10-39
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
4) When pump load is large in pump prolix switch ON
•
When main pump discharge pressure PA1 (or PA2) increases, spool (2) is moved up by piston (4) or piston (6). As a result, the flow of oil from port a to port b is throttled by the notch in the spool. At the same time, the area of the opening at port b and port c (drain port) becomes larger. In this way, TVC output pressure Pe goes down, and the pump discharge amount decreases.
10-40
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
6. No. 1 pump front CO, NC valve
10-42
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CO valve 1. Plug 2. Piston 3. Spring 4. Spool 5. Piston 6. Plug
HYDRAULIC PUMP
NC valve 7. Plug 8. Sleeve 9. Piston 10. Spool 11. Spring 12. Plug
PA1 : Main pump pressure IN port Pe1 : TVC valve output pressure front, rear interconnection port Pc : CO selector port Pd : Jet sensor downstream pressure IN port : Jet sensor upstream pressure IN port Pt Pdr2 : CO, NC valve drain OUT port Pecn : CO, NC valve output pressure OUT port
PC750, 800-7
10-43
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
7. No. 1 pump rear CO, NC valve
10-44
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CO valve 1. Plug 2. Piston 3. Spring 4. Spool 5. Piston 6. Plug
HYDRAULIC PUMP
NC valve 7. Plug 8. Sleeve 9. Piston 10. Spool 11. Spring 12. Plug
PA1i : Main pump pressure IN port PA1o: Main pump pressure OUT port PA2i : Main pump pressure IN port PA2o: Main pump pressure OUT port Pe1 : TVC valve output pressure front, rear interconnection port Pe2 : TVC valve output pressure IN port Pc : CO selector pilot port Pd : Jet sensor downstream pressure IN port : Jet sensor upstream pressure IN port Pt Pdr1 : TVC valve drain IN port Pdr2 : CO, NC valve drain OUT port Psv1 : Servo basic pressure IN port Psv2 : Servo basic pressure OUT port Pecn : CO, NC valve output pressure OUT port
PC750, 800-7
10-45
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
Function and operation of CO valve 1) When main pump discharge pressure is lower than relief pressure
Function • When the load becomes large during operations and the main pump discharge pressure rises to a point close to relief pressure, the cut-off function of the CO valve acts to reduce the pump discharge in order to reduce relief loss. • At the same time, it has a cut-off cancel function actuated by the pilot pressure from the heavy-lift solenoid valve. • The CO valve is controlled by balancing the spring with the total of main pump discharge pressure PA and CO valve output pressure Pec.
10-46
Operation • Spool (4) is being pushed down fully by spring (3). As a result, port a and port b are fully open and TVC valve output pressure Pe and CO valve output pressure Pec are equal. In this way, CO valve output pressure Pec becomes the maximum and the main pump discharge amount also becomes the maximum.
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
2) When main pump discharge pressure becomes close to relief pressure
•
If the load increases and main pump discharge pressure PA comes close to the relief pressure, main pump discharge pressure PA pushes piston (5). At the same time, CO valve output pressure Pec pushes piston (5), and spool (4) moves up. As a result, the flow of oil from port a to port b is throttled by the notch in the spool, and the area of the opening at port b and port c (drain port) becomes larger. In this way, CO valve output pressure Pec goes down, and the pump discharge amount becomes the minimum.
PC750, 800-7
10-47
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
3) When cut-off function is canceled by heavy-lift solenoid valve
•
When the heavy-lift solenoid valve is excited and is switched, pilot pressure Pc is sent to the port, and piston (2) is pushed down fully. For this reason, seat (6) contacts seat (7) and spool (4) is locked. As a result, main pump discharge pressure PA goes up, but even when it reaches the relief pressure, spool (4) is not actuated, so CO valve output pressure Pec remains at the maximum.
10-48
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
Function and operation of NC valve 1) When control valve is at neutral
Function • The NC valve controls the main pump discharge amount according to the amount that the control valve spool is operated. This flow control function reduces the neutral loss and fine control loss. • The NC valve is controlled by balancing the total of the jet sensor output pressure Pt and the NC valve output pressure Pecn with the total of the force of NC valve spring (12) and the jet sensor output pressure Pd. • The jet sensor picks up the flow of oil returning to the tank through the control valve and takes them as Pt and Pd of the NC valve.
PC750, 800-7
Operation • Jet sensor differential pressure (Pt – Pd) becomes the maximum, and the force of jet sensor output pressure Pt pushing piston (10) becomes larger than the total of the force of spring (12) and the force of jet sensor output pressure Pd pushing the bottom of spool (11). As a result, spool (11) is pushed down, so the flow to port c and port b is throttled, and the area of the opening of port b and port a (drain port) becomes larger. In this way, NC valve output pressure Pecn becomes the minimum, and the main pump discharge amount also becomes the minimum.
10-49
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
2) When control lever is operated
•
When the control valve is moved, the jet sensor differential pressure (Pt – Pd) goes down in accordance with the movement of the control valve. Spool (11) is pushed up, and the area of the opening of port c and port b becomes larger. In this way, NC valve output pressure Pecn becomes larger and the discharge amount from the main pump increases. In other words, the pump discharge amount increases according to the amount the control lever is operated.
10-50
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
NO. 2 PUMP ASSEMBLY HPV95 + 95
1. 2. 3. 4.
Front pump Front servo valve Rear servo valve Rear pump
PC750, 800-7
PA1 : Discharge port PA2 : Discharge port Pd11 : Drain port Pd21 : Drain port Ps : Suction port Psv : Servo basic pressure IN port Pecn : CO, NC valve output pressure IN port
10-51
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
1. No. 2 main pump
Psv1 : Servo valve basic pressure port Psv1A : Servo piston output pressure port Psv1B : Servo valve output pressure port Psv2 : Servo valve basic pressure port Psv2A : Servo piston output pressure port Psv2B : Servo valve output pressure port
10-52
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6. 7.
Front shaft Front cradle Front case Rocker cam Piston Cylinder block Valve plate
PC750, 800-7
8. 9. 10. 11. 12. 13. 14.
Front end cap Coupling Impeller Rear end cap Valve plate Cylinder block Piston
HYDRAULIC PUMP
15. 16. 17. 18. 19.
Rear case Rocker cam Rear cradle Rear shaft Servo piston
10-53
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
2. No. 2 pump front servo assembly
1. Servo valve
10-54
PA1 PA2 Pac Pdr Psv Pecn
: Main pump pressure IN port : Main pump pressure IN port : Servo actuator port : Servo valve drain OUT port : Servo basic pressure IN port : CO, NC valve output pressure IN port
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
3. No. 2 pump rear servo assembly
1. Servo valveassembly
PC750, 800-7
PA2 Pac Pav Pecn Pdr P1
: : : : : :
Main pump pressure IN port Servo actuator port Servo basic pressure IN port CO, NC valve output pressure detection IN port Servo valve drain OUT port Pilot pressure IN port
10-55
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETURN OIL FILTER
RETURN OIL FILTER
1. 2. 3. 4. 5. 6.
Cover Spring Bypass valve Bypass valve spring Element Housing
A. From control valve B. To hydraulic tank
10-56
Outline There are two return oil filters installed to the rear face of the hydraulic tank. They remove the dirt and dust in the return oil. Specifications • Bypass valve set pressure: 0.15 ± 0.03 MPa {1.5 ± 0.3 kg/cm2}
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LINE OIL FILTER PILOT OIL FILTER
LINE OIL FILTER
1. Element 2. Body 3. Cover
PILOT OIL FILTER 1. Bracket 2. Cartridge 3. Element
PC750, 800-7
10-57
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
DRAIN OIL FILTER
DRAIN OIL FILTER 1. Cartridge 2. Safety valve 3. Bracket
10-58
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
L.H. 5-SPOOL CONTROL VALVE
L.H. 5-SPOOL CONTROL VALVE P T A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 P1 PP TC PA1 PA2 PA3 PA4 PA5 PB1 PB2 PB3 PB4 PB5 PC1 PC2 NCA NCB
: From rear pump : To tank (Main drain) : To boom cylinder bottom : To swing motor port MA (Swing RIGHT) : To arm cylinder bottom : To bucket cylinder bottom : To travel motor (Left travel port P2) : Plug : To swing motor (Port MB) : To arm cylinder head : Plug (Standard machine) : To travel motor (Left travel port P1) : Valve (From straight travel valve port P2 of right 4-spool valve) : From straight travel changeover solenoid valve : Drain : From PPC valve (Boom LOWER) : From PPC valve (Swing LEFT) : From PPC valve (Arm OUT) : Standard; Bucket DUMP PPC valve or drain Optional: Optional PPC valve (via shuttle valve) : From PPC valve (Left travel FORWARD) : From PPC valve (Boom RAISE) : From PPC valve (Swing RIGHT) : From PPC valve (Arm IN) : From PPC valve (Bucket CURL) : From PPC valve (Left travel REVERSE) : From pilot valve (Port A2) : From pilot valve (Port A1) : To pump (NC valve J/S upstream pressure) : To pump (NC valve J/S downstream pressure)
10-60
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PC750, 800-7
L.H. 5-SPOOL CONTROL VALVE
10-61
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6.
Main relief valve Spool (boom Hi) Spool (swing) Spool (arm Lo) Spool (bucket Hi) Spool (L.H. travel)
10-62
7. 8. 9. 10. 11. 12.
Spool return spring Valve body Jet sensor orifice Jet sensor relief valve Throttle valve Check valve spring
L.H. 5-SPOOL CONTROL VALVE
13. 14. 15. 16.
Check valve Suction-safety valve Suction valve Check valve with orifice
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-64
L.H. 5-SPOOL CONTROL VALVE
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
L.H. 5-SPOOL CONTROL VALVE
Unit: mm No.
Check item
Criteria
Remedy
Standard size 1
Main relief valve, main valve spring
Repair limit
Free length × OD
Installation length
Installation load
Free length
Installation load
34.7 × 10.1
32.5
394.2 N {40.2 kg}
—
315.2 N {32.2 kg}
2
Jet sensor relief valve, pilot poppet spring
34.5 × 8.8
29.4
30 N {3.1 kg}
—
24.3 N {2.5 kg}
3
Jet sensor relief valve, main valve spring
37.4 × 11.4
33
49 N {5.0 kg}
—
39.2 N {4.0 kg}
4
Spool return spring
69.9 × 57
63
431 N {44 kg}
—
345 N {35.2 kg}
5
Spool return spring
75 × 37
74.3
0N {0 kg}
—
0N {0 kg}
6
Throttle valve spring
31.8 × 7.6
26.5
1N {0.1 kg}
—
0.78 N {0.08 kg}
7
Check valve spring
78.2 × 26.6
52
18.8 N {1.92 kg}
—
15.1 N {1.54 kg}
8
Check valve spring (throttle valve)
65.3 × 14
46
18.8 N {1.92 kg}
—
15.1 N {1.54 kg}
PC750, 800-7
Replace spring if damaged or deformed
10-65
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
R.H. 4-SPOOL CONTROL VALVE
R.H. 4-SPOOL CONTROL VALVE P T A1 A2 A3 A4 B1 B2 B3 B4 P1 P2 PP PR PS PT PA1 PA2 PA3 PA4 PB1 PB2 PB3 PB4 NCA NCB
: From front pump : To tank : To travel motor (Right travel port P1) : To boom cylinder head : To bucket cylinder bottom : To arm cylinder head : To travel motor (Right travel port P2) : To boom cylinder bottom : To bucket cylinder head : To arm cylinder bottom : From rear pump : To left 5-spool valve port P1 : From straight travel changeover solenoid valve : From 2-stage main relief valve changeover solenoid valve : From 2-stage safety valve changeover solenoid valve : Drain : From PPC valve (Right travel FORWARD) : From PPC valve (Boom RAISE) : From PPC valve (Bucket DUMP) : From PPC valve (Arm IN) : From PPC valve (Right travel REVERSE) : From PPC valve (Boom LOWER) : From PPC valve (Bucket CURL) : From PPC valve (Arm OUT) : To pump (NC valve J/S upstream pressure) : To pump (NC valve J/S downstream pressure)
10-66
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PC750, 800-7
R.H. 4-SPOOL CONTROL VALVE
10-67
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5.
Main relief valve Spool (R.H. travel) Spool (boom Lo) Spool (bucket Lo) Spool (arm Hi)
10-68
6. 7. 8. 9. 10.
Spool return spring Valve body Jet sensor orifice Jet sensor relief valve Check valve
R.H. 4-SPOOL CONTROL VALVE
11. 12. 13. 14. 15.
Check valve spring Straight-travel valve Suction valve Suction-safety valve Suction-safety valve
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-70
R.H. 4-SPOOL CONTROL VALVE
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
R.H. 4-SPOOL CONTROL VALVE
Unit: mm No.
Check item
Criteria
Remedy
Standard size 1
Main relief valve, main valve spring
Repair limit
Free length × OD
Installation length
Installation load
Free length
Installation load
34.7 × 10.1
32.5
394.2 N {40.2 kg}
—
315.2 N {32.2 kg}
2
Jet sensor relief valve, pilot poppet spring
34.5 × 8.8
29.4
30 N {3.1 kg}
—
24.3 N {2.5 kg}
3
Jet sensor relief valve, main valve spring
37.4 × 11.4
33
49 N {5.0 kg}
—
39.2 N {4.0 kg}
4
Spool return spring
69.9 × 57
63
431 N {44 kg}
—
345 N {35.2 kg}
5
Spool return spring
75 × 37
74.5
0N {0 kg}
—
0 N {0 kg}
6
Check valve spring
78.2 × 26.6
52
18.8 N {1.92 kg}
—
15.1 N {1.54 kg}
7
Check valve spring
41.3 × 35.5
25.5
18.8 N {1.92 kg}
—
15.1 N {1.54 kg}
PC750, 800-7
Replace spring if damaged or deformed
10-71
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STRAIGHT-TRAVEL VALVE
STRAIGHT-TRAVEL VALVE
P PP PT P1 P2 P3 P4
: : : : : : :
From pump (Front) From straight travel changeover solenoid valve Drain From pump (Rear) To left travel (Left 5-spool control valve) To bucket and boom To arm
10-72
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6. 7.
STRAIGHT-TRAVEL VALVE
Orifice Check valve Spring Spool return spring Body Spool Cover
PC750, 800-7
10-73
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STRAIGHT-TRAVEL VALVE
Function • When the travel is operated at the same time as the boom, arm, or bucket, the pressure oil flowing to the left and right travel circuits is divided and sent to the boom, arm, or bucket circuit. If the oil in one travel circuit is divided off, the amount of oil supplied to the travel motor will be less than in the travel circuit which is not divided, so the drop in the supply of oil to the travel motor will cause the machine to deviate. • To prevent this, the straight-travel valve is switched to interconnect the left and right travel circuits. This ensures that the amount of oil supplied to the left and right travel motors is equal, so the left and right travel motors both rotate at the same speed, and this prevents any travel deviation. Operation When travel is operated independently (straighttravel solenoid valve de-energized) • The straight-travel solenoid valve is de-energized, so no pilot pressure flows, and spool (6) remains pushed to the right. • Because of this, port P2 (left travel circuit) and port P1 (right travel circuit) are not interconnected, and each circuit remains independent.
When travel and work equipment are operated at same time (straight-travel solenoid valve excited) • The straight-travel solenoid valve is excited, so the pilot pressure flows and spool (6) is pushed to the left. • Because of this, port P2 and port P1 are interconnected, so the amount of oil supplied to the left and right travel motors is the same. As a result, the left and right travel motors both rotate at the same speed, so there is no travel deviation.
10-74
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MOTOR
SWING MOTOR KMF125AB-5
B : From swing lock solenoid valve S : From back pressure compensation valve T : To tank MA : From control valve MB : From control valve
PC750, 800-7
Specifications Model : KMF125AB-5 Theoretical displacement : 125.0 cm3/rev Safety valve set pressure : 27.9 MPa {285 kg/cm2} Rated revolving speed : 1,936 rpm Brake release pressure : 1.9 MPa {19 kg/cm2}
10-75
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6.
Brake spring Drive shaft Spacer Case Disc Plate
10-76
7. 8. 9. 10. 11. 12.
Brake piston Housing Piston Cylinder block Valve plate Center shaft
SWING MOTOR
13. 14. 15. 16. 17. 18.
Center spring Safety valve Check valve Check valve spring Shuttle valve Shuttle valve spring
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MOTOR
Unit: mm No.
Check item
Criteria
Remedy
Standard size
1
2
Check valve spring
Shuttle valve spring
PC750, 800-7
Repair limit
Free length × Outside diameter
Installed length
Installed load
Free length
Installed load
62.5 × 20.0
35
3.5 N {0.36 kg}
—
2.8 N {0.29 kg}
16.4 × 8.9
11.5
13.7 N {1.4 kg}
—
10.8 N {1.1 kg}
If damaged or deformed, replace spring
10-77
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MOTOR
RELIEF VALVE PORTION 1. Outline The relief portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). 2. Function When the swing is stopped, the outlet port circuit of the motor from the control valve is closed, but the motor continues to rotate under inertia, so the pressure at the output side of the motor becomes abnormally high, and this may damage the motor. To prevent this, the abnormally high pressure oil is relieved to port S from the outlet port of the motor (high-pressure side) to prevent any damage. 3. Operation 1) When starting swing • When the swing control lever is operated to swing right, the pressure oil from the pump passes through the control valve and is supplied to port MA. As a result, the pressure at port MA rises, the starting torque is generated in the motor, and the motor starts to rotate. The oil from the outlet port of the motor passes from port MA thought the control valve and returns to the tank. (Fig. 1) 2) When stopping swing • When the swing control lever is returned to neutral, the supply of pressure oil from the pump to port MA is stopped. With the oil from the outlet port of the motor, the return circuit to the tank is closed by the control valve, so the pressure at port MB rises. As a result, rotation resistance is generated in the motor, so the braking effect starts. • If the pressure at port MB becomes higher than the pressure port MA, it pushes shuttle valve A (4) and chamber C becomes the same pressure as port MB. The oil pressure rises further until it reaches the set pressure of relief valve (1). As a result, a high braking torque acts on the motor and stops the motor. (Fig. 2) • When relief valve (1) is being actuated, the relief oil and the oil from port S passes through check valve B (3) and is supplied to port MA. This prevents cavitation at port MA.
10-78
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MOTOR
Operation of swing brake 1) When swing brake solenoid valve is de-energized If the swing brake solenoid valve is de-energized, the flow of pressurized oil from the control pump is shut off, and port B is connected to the tank circuit. As a result, brake piston (6) is pushed down by brake spring (7), pushes disc (5) and plate (4) together, and the brake is applied.
2) When swing brake solenoid valve is excited When the swing brake solenoid valve is energized, the valve is switched, and pressurized oil from the control valve enters port B and flows to brake chamber a. The pressurized oil entering chamber a overcomes brake spring (7) and pushes brake piston (6) up. As a result, disc (5) and plate (4) are separated and the brake is released.
PC750, 800-7
10-79
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
1. 2. 3. 4. 5.
Cover Body Slipper seal Oil seal Shaft Unit: mm
No.
Check item
6
Clearance between rotor and shaft
10-80
Criteria
Remedy
Standard size
Standard clearance
Clearance limit
110
0.056 – 0.105
0.111
Replace
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
TRAVEL MOTOR MSF-340VP-EH
1. Travel selector valve 2. Motor 3. Travel brake valve P1 P2 PI T
: From control valve : From control valve : From travel speed solenoid valve : To hydraulic tank
PC750, 800-7
Specifications Model Theoretical delivery
: MSF-340VP-EH : 1st 337.2 cc/rev : 2nd 212.6 cc/rev Rated pressure : 31.4 MPa {320 kg/cm2} Rated speed : 1st 1,423 rpm (at 500 l /min.) : 2nd 2,258 rpm (at 500 l /min.) Brake release pressure : 1.8 MPa {18.4 kg/cm2}
10-81
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
1. Travel motor, travel speed selector valve, relief valve
1. Travel speed selector valve 1a. Spool 1b. Spring
10-82
2. Relief valve 2a. Shockless piston 2b. Poppet PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
3. 4. 5. 6. 7. 8. 9.
Rear cover Collar Valve plate Cylinder block assembly Piston assembly Holder Retainer
PC750, 800-7
10. 11. 12. 13. 14. 15. 16.
Piston assembly Case Shaft Bearing collar Rocker cam Preload spring Disc
TRAVEL MOTOR
17. Plate 18. Brake piston 19. Spring
10-83
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
1-1 Motor
•
There are 9 pistons (7) assembled in cylinder block (6). The end face of the cylinder block has a spherical surface and is in contact with valve plate (5), which has two half-moon shaped ports (divider valve for high/low speed selector).
•
The fixed surface (contact surface with the motor case) forming the non-sliding surface of rocker cam (14) has two faces. The high/low speed volume selection for this motor is carried out by fixing each face to provide large capacity (low speed) or small capacity (high speed). The angling operation of rocker cam (14) is carried out by actuating control piston (10) with the self-pressure through the speed selector valve when the motor is being driven, and this angles the rocker cam. There are two control pistons each for the high/ low pressure divider ports of valve plate (5), and these provide propulsion force to the rocker cam.
10-84
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
1-2 Speed selector valve Operation 1) At low speed (pilot pressure PI = 0)
•
When pilot pressure PI from the control pump is 0, spool (1a) of travel speed selector valve (1) is not switched. In this condition, the oil from the chamber of control piston (10) passes through spool (1a) and is drained into the motor case. There is no angle propulsion force acting on rocker cam (14), so the low-speed surface is kept in a static condition.
PC750, 800-7
10-85
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
2) At high speed (automatic 2nd)
•
When the pilot signal is ON, pilot pressure PI from the control pump acts on travel speed selector valve (1) and the capacity is automatically changed by the drive pressure of the travel motor. Balance of force for travel speed selector valve F1 [Force pushing spool (1a) to right (highspeed side)] = A (area of spool (1a) receiving pressure) × PI F2 [Force pushing spool (1a) to left (low-speed side)] = A (area of spool (1a) receiving pressure) × PH (motor drive pressure) + force of spring (1b) i)
10-86
When traveling on level ground, if the travel motor drive pressure is low, the condition becomes F1 > F2, and spool (1a) is pushed to the right. When this happens, the main oil pressure (M1, M2) passes through spool (1a) and
ii)
goes to the control piston chamber. Rocker cam (14) overcomes moment Mx with hydraulic force from propulsion force Fc of control piston (10). It rotates and holds the moment balance at the high speed surface and is held in position (Mx < Fc, L). When operating the steering or traveling uphill, if the motor drive pressure is high, and it goes above the set pressure, the condition becomes F1 < F2, and spool (1a) is pushed to the left. When this happens, the main oil pressure (M1, M2) passes through spool (1a) and is drained to the motor case. This creates the low-speed condition in the same way as when PI = 0.
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
1-3 Parking brake The parking brake is a hydraulic release, wet type, multiple disc negative brake. The release pressure employs a self-pressure release method using the travel motor drive pressure through the oil passage in the counterbalance valve spool of the travel brake valve. When the machine is traveling, the drive pressure is sent to port P of the parking brake circuit, acts on the piston in the brake cylinder chamber, overcomes the force of the spring and releases the brake. When the machine is parked or stopped, the counterbalance valve spool returns to neutral, and the oil in the cylinder chamber is released to the tank through the counterbalance valve spool, so the brake is applied by the force of the spring to mechanically lock the motor shaft and hold the machine in position. When parking brake is ON When the travel lever is placed in neutral, the counterbalance valve spool returns to the neutral position and parking brake circuit P is closed. The pressurized oil in chamber e of the brake piston passes through the counterbalance valve spool, is drained to the tank, and brake piston (18) is pushed fully to the left by force Fs of spring (19), and the brake is applied. When parking brake is OFF When the travel lever is operated, the pressurized oil from the pump actuates the counterbalance valve spool, opens the circuit to the parking brake, and flows into chamber e of brake piston (18). It overcomes the force of spring (19), and pushes brake piston (18) to the right. When this happens, the force pushing plate (17) and disc (16) together is lost, so the plate and disc separate and the brake is released.
PC750, 800-7
10-87
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
1-4 Relief valve
1. 2. 3. 4. 5.
Shockless piston Poppet Poppet orifice Relief housing orifice Piston stroke
Function In addition to the pressure control function, this relief valve has a shockless function (2-stage pressure increase function). This acts to reduce the shock generated at the beginning when the speed is reduced (when the machine is stopped). Operation 1) When relief valve starts to be actuated (1st stage) The area receiving the pressure which lifts poppet (2) becomes area S1 of the poppet seat. For this reason, it has a much larger pressurereceiving area than the pressure-receiving area when it is set (S1 – S2), so the relief actuating pressure becomes a low pressure of approx. 15.7 MPa {160 kg/cm2}. This condition is maintained until the movement of shockless piston (1) is completed (approx. 0.25 sec). 2) When movement of shockless piston is completed (2nd stage) The pressure in the relief valve spring chamber rises, the pressure on both sides of poppet (2) becomes the same, and it becomes the specified set pressure. a Set pressure and amount of adjustment Amount of adjustment for one turn: Approx. 7.8 MPa {80 kg/cm2}
10-88
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
1-5 Travel brake valve
Function • The brake valve consists of counterbalance valve (3) and check valve (4). • The counterbalance valve acts to prevent the piston motor from stopping or overrunning. • When traveling downhill, the weight of the machine makes it try to travel at a speed faster than the rotation of the motor. For this reason, if the machine is traveling with the engine running at low speed, the motor will rotate under no load or may run away, which is extremely dangerous. To prevent this, this valve controls the amount of oil on the return side in order to keep the valve pressure constant, and makes it possible to carry out travel operations which match the oil delivery from the motor.
PC750, 800-7
1. 2. 3. 4. 5.
Cap assembly Return spring Counterbalance valve Check valve Check valve spring
Specification Safety valve set pressure: 34 MPa {350 kg/cm2} Counterbalance switching pressure: 1.0 ± 0.1 MPa {10 ± 1 kg/cm2} Check valve switching pressure: 0.02 ± 0.01 MPa {0.2 ± 0.1 kg/cm2}
10-89
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
Operation when oil is supplied • When the travel lever is operated, the pressurized oil from the control valve is supplied to port P1. It pushes open check valve (5a) and flows from motor inlet port M1 to motor outlet port M2. However, the motor outlet port is closed by check valve (5b) and spool (3), so the pressure at the supply side rises.
•
The pressurized oil at the supply side flows from orifice a in spool (3) to chamber A. When the pressure in chamber A goes above the spool switching pressure, spool (3) is pushed to the left. As a result, port M2 and port P2 are connected, the outlet port side of the motor is opened, and the motor starts to rotate.
Operation of brake when traveling downhill • If the machine tries to run away when traveling downhill, the motor will turn under no load, so the pressure at the motor inlet port will drop, and the pressure in chamber A through orifice a will also drop. When the pressure in chamber A drops below the spool switching pressure, spool (3) is returned to the right by spring (2), and outlet port M2 is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor, and this prevents the machine from running away. In other words, spool (3) moves to a position where the pressure at outlet port M2 balances the pressure at the inlet port and the force generated by the weight of the machine. It throttles the outlet port circuit and controls the travel speed according to the amount of oil discharged from the pump.
10-90
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC CONTROL RELIEF VALVE
PPC CONTROL RELIEF VALVE
1. 2. 3. 4.
Valve body Check valve spring Check valve Relief valve
A. B. C. D. E.
From control pump From PPC valve Pump drain Motor drain Pump drain
Specifications Set pressure: 3.1
F. G. H. T.
+0.3 0
MPa {32
+3 0
kg/cm2} (at 135 l/min)
To PPC valve To servo valve To accumulator To tank Unit: mm
No.
Check item
Criteria
Remedy
Standard size 5
Check valve spring
PC750, 800-7
Repair limit
Free length × OD
Installation length
Installation load
Free length
Installation load
56 × 21.4
37
70.6 N {0.72 kg}
—
5.65 N {0.58 kg}
Replace
10-91
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC ACCUMULATOR
PPC ACCUMULATOR 1. 2. 3. 4. 5. 6.
Gas plug Shell Poppet Holder Bladder Oil port
Specifications Type of gas : Nitrogen gas Gas volume : 300 cc Max. actuating pressure : 3.1 MPa {32 kg/cm2} Min. actuating pressure : 1.2 MPa {12 kg/cm2}
Function • The accumulator is installed between the PPC control pump and the PPC valve. Even if the engine is stopped with the work equipment raised, pilot oil pressure is sent to the main control valve by the pressure of the nitrogen gas compressed inside the accumulator, so it is possible to lower the work equipment under its own weight. Operation • After the engine stops, when the PPC valve is at neutral, chamber A inside the bladder is compressed by the oil pressure in chamber B. • If the PPC valve is operated, the oil pressure in chamber B becomes less than 2.9 MPa {30 kg/ cm2}, so the bladder expands under the pressure of the nitrogen gas in chamber A. The oil entering chamber B is sent as the pilot pressure to actuate the main control valve.
10-92
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
VALVE CONTROL
VALVE CONTROL
1. 2. 3. 4. 5. 6. 7. 8. 9.
R.H. 4-spool control valve L.H. 5-spool control valve Accumulator No. 1 pump Control pump No. 2 pump PPC control relief valve Shockless boom valve Safety lock valve
PC750, 800-7
10. 11. 12. 13. 14. 15. 16. 17.
Safety lock lever Left PPC valve Left work equipment lever Travel PPC valve L.H. travel lever R.H. travel lever Right PPC valve Right work equipment lever
Lever positions [1] HOLD [2] Boom RAISE [3] Boom LOWER [4] Bucket DUMP [5] Bucket CURL [6] HOLD [7] Arm IN [8] Arm OUT [9] Swing right [10] Swing left [11] Neutral [12] Travel REVERSE [13] Travel FORWARD [14] LOCK [15] FREE
10-93
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT, SWING PPC VALVE
WORK EQUIPMENT, SWING PPC VALVE
P. From control pump T. To hydraulic tank P1. Left: Arm IN, Right: Boom RAISE
10-94
P2. Left: Arm OUT, Right: Boom LOWER P3. Left: Swing left, Right: Bucket DUMP P4. Left: Swing right, Right: Bucket CURL
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5.
Spool Metering spring Centering spring Piston Disc
10-96
6. 7. 8. 9. 10.
WORK EQUIPMENT, SWING PPC VALVE
Nut (for connecting lever) Joint Plate Retainer Body
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT, SWING PPC VALVE
Unit: mm No.
Check item
Criteria
Remedy
Standard size 11
Centering spring (for P3, P4)
Repair limit
Free length × OD
Installation length
Installation load
Free length
Installation load
42.48 × 15.5
34
17.6 N {1.8 kg}
—
13.7 N {1.4 kg}
12
Metering spring
26.7 × 8.14
24.9
16.6 N {1.69 kg}
—
13.2 N {1.35 kg}
13
Centering spring (for P1, P2)
38.71 × 15.5
34
9.8 N {1 kg}
—
7.8 N {0.8 kg}
PC750, 800-7
Replace spring if damaged or deformed
10-97
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT, SWING PPC VALVE
Operation 1) At neutral Ports A and B of the control valve and ports P1, P2, P3, and P4 of the PPC valve are connected to drain chamber D at the bottom. (Fig. 1)
2) Fine control (neutral o fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed. Spool (1) is also pushed by metering spring (2) and moves down. When this happens, port P1 is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure of the control pump is sent from port P1 to port A. When the pressure at port P1 rises, spool (1) is pushed back. Port P1 is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D, so the pressure at port P1 escapes. As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure of port P1. The relationship of the positions of spool (1) and body (10) does not change until retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. In this way, the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port P1) and the force of the return spring of the control valve spool are balanced.
10-98
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT, SWING PPC VALVE
3) Fine control (control lever returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, port P1 is connected to drain chamber D, and the pressurized oil at port P1 is released. If the pressure at port P1 drops too much, spool (1) is pushed down by metering spring (2), so port P1 is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port P1 supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve returns, oil in drain chamber D flows in from the valve on the side that is not moving. It passes through port P2 and goes to chamber B to charge the oil.
4) At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1), port P1 is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from the control pump flows to chamber A from port P1 to push the control valve spool. The return oil from chamber B passes from port P2 and flows to drain chamber D.
PC750, 800-7
10-99
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL PPC VALVE
TRAVEL PPC VALVE
P T P1 P2 P3 P4
: From control pump : To tank : Left travel forward : Left travel reverse : Right travel forward : Right travel reverse
10-100
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4.
Plate Body Piston Collar
5. 6. 7. 8.
TRAVEL PPC VALVE
Centering spring Metering spring Valve Bolt Unit: mm
No.
Check item
Criteria Basic dimension
9
10
Metering spring
Centering spring
PC750, 800-7
Remedy Allowable limit
Free length × Outside diameter
Installed length
Installed load
Free length
Installed load
26.7 × 8.14
24.9
16.6 N {1.69 kg}
—
13.7 N {1.40 kg}
48.57 × 15.5
32.5
107.9 N {11 kg}
—
86.3 N {8.8 kg}
If damaged or deformed, replace spring
10-101
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL PPC VALVE
Operation 1. At neutral • Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1)
2. During fine control (neutral o fine control) • When piston (4) starts to be pushed by disc (5), retainer (9) is pushed; spool (1) is also pushed by metering spring (2) and moves down. • When this happens, fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure of the control pump is sent from port A through fine control hole f to port P1. • When the pressure at port P1 rises, spool (1) is pushed back. Fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D to release the pressure at port P1. • As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure of port P1. • The relationship in the position of spool (1) and body (10) (fine control hole f is in the middle between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1). • Therefore, metering spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. • In this way, the control valve spool moves to a position where the pressure of chamber A (same as pressure at port P1) and the force of the return spring of the control valve spool are balanced. (Fig. 2)
10-102
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL PPC VALVE
3. Fine control (control lever returned) • When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port P1 is released. • If the pressure at port P1 drops too much, spool (1) is pushed up by metering spring (2), so fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port P1 supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. • When the control valve returns, oil in drain chamber D flows in from fine control hole f ’ of the valve on the side that is not moving. It passes through port P2 and enters chamber B to fill the chamber with oil. (Fig. 3)
4. At full stroke • Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1). Fine control hole f is shut off from drain chamber D, and is connected to pump pressure chamber PP. • Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port P1 to push the control valve spool. • The return oil chamber B passes from port P2 through fine control hole f ’ and flows to drain chamber D. (Fig. 4)
PC750, 800-7
10-103
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SOLENOID VALVE
SOLENOID VALVE For resetting CO, straight travel, heavy lifting, pushing up machine, travel speed (at center of machine body)
1. 2. 3. 4. 5.
CO resetting solenoid valve Straight travel solenoid valve Heavy lift solenoid valve Machine push-up solenoid valve Travel speed solenoid valve
10-104
T A1 A2 A3 A4 A5 P1 ACC PPC
: : : : : : : : :
To tank To No. 1 pump (CO valve) To boom LOWER 2-stage safety valve To main valve (Relief valve) To straight travel valve To left and right travel motor From control pump Plug Plug
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SOLENOID VALVE
1. 2. 3. 4. 5. 6. 7.
Connector Movable core Coil Cage Spool Block Spring
Operation When solenoid is de-energized • When the signal current does not flow from the PPC lock switch or swing lock switch, solenoid (3) is de-energized. • For this reason, spool (5) is pushed fully to the left by spring (6). • As a result, the circuit between ports P and A closes and the pressurized oil from the control pump does not flow to the actuator. • At the same time, the pressurized oil from the actuator flows from port A to port T, and is then drained to the tank.
When solenoid is energized • When the signal current flows from the PPC lock switch or swing lock switch to solenoid (3), solenoid (3) is energized. For this reason, spool (5) is pushed to the right in the direction of the arrow. As a result, the pressurized oil from the control pump flows from port P through the inside of spool (5) to port A, and then flows to the actuator. At the same time, port T is closed, and this stops the oil from flowing to the tank.
PC750, 800-7
10-105
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SOLENOID VALVE
For swing holding brake (on right side of machine body), for safety lock (under cab)
For swing holding brake 1. Swing holding brake solenoid valve
For safety lock 1. Safety lock solenoid valve
T : To tank A : To front and rear swing motors P : From control pump
T : To tank A : To port P of work equipment PPC valve To port P of travel PPC valve P : From control pump
10-106
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6.
Connector Solenoid Variable iron core Body Plug Spring
7. 8. 9. 10. 11.
SOLENOID VALVE
Spool Body Plug Spring Spool
Operation When solenoid is de-energized • No signal current flows from the controller, so solenoid (2) is de-energized. • Accordingly, spool (11) is pushed up and spool (7) is pushed to the left by spring (6). • As a result, port P is closed, so pressure oil from the control pump does not flow to the actuator. At the same time, the oil from the actuator flows from port A2 to port T and is drained to the tank. When solenoid is energized • When the signal current flows from the controller to solenoid (2), solenoid (2) is energized. • Accordingly, spool (11) is pushed down and the pressure oil from the control pump flows through port P to port A1 and spool (7) is pushed to the right. • As a result, pressure oil from the control pump flows from port P to port A2, and then flows to the actuator. At the same time, port T is closed, so the oil does not flow to the tank.
PC750, 800-7
10-107
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SOLENOID VALVE
For swing priority (On left side of machine body)
1. Swing priority solenoid valve T : To tank A : To 5-spool control valve P : From control pump
10-108
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SOLENOID VALVE
1. 2. 3. 4. 5. 6. 7.
Connector Movable iron core Coil Spool Body Spring Plug
Operation When solenoid is de-energized • The signal current does not flow from the controller, so coil (3) is de-energized. For this reason, spool (4) is returned to the neutral position by spring (6). As a result, the circuit between ports P and A is connected, and the pressurized oil from the PPC valve flows to the control valve.
When solenoid is energized • When the signal current flows from the controller to coil (3), coil (3) is energized and movable iron core (2) is pushed to the right in the direction of the arrow. • For this reason, spool (4) is also pushed to the right in the direction of the arrow. As a result, port P is closed, and the pressure oil from the control pump does not flow to the control valve. At the same time, port A and port T are interconnected, and the oil from the control valve is drained to the tank.
PC750, 800-7
10-109
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER BACKHOE SPECIFICATION PC750, 750LC, 800-7 STD BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-110 (3)
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC CYLINDER
Unit: mm No.
1
2
3
Check item
Clearance between piston rod and bushing
Clearance between piston rod support shaft and bushing
Clearance between cylinder bottom support shaft and bushing
PC750, 800-7
Criteria
Name of cylinder
Standard size
Boom
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
140
–0.043 –0.106
+0.256 +0.039
0.082 – 0.362
0.062
Arm
140
–0.043 –0.106
+0.256 +0.039
0.082 – 0.362
0.062
Bucket
120
–0.036 –0.090
+0.263 +0.048
0.084 – 0.353
0.062
Boom
115
–0.036 –0.090
+0.025 0
0.036 – 0.115
1.5
Arm
115
–0.036 –0.090
+0.025 0
0.036 – 0.115
1.5
Bucket
110
–0.036 –0.090
+0.457 +0.370
0.406 – 0.547
1.5
Boom
130
–0.043 –0.106
+0.025 0
0.043 – 0.131
1.5
Arm
130
–0.043 –0.106
+0.025 0
0.043 – 0.131
1.5
Bucket
110
–0.036 –0.090
+0.457 +0.370
0.406 – 0.547
1.5
Replace bushing
Replace pin, bushing
10-111
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC CYLINDER
PC750SE, 800SE-7 BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-112
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC CYLINDER
Unit: mm No.
1
2
3
Check item
Clearance between piston rod and bushing
Clearance between piston rod support shaft and bushing
Clearance between cylinder bottom support shaft and bushing
PC750, 800-7
Criteria Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
140
–0.043 –0.106
+0.256 +0.039
0.082 – 0.362
0.062
Arm
120
–0.036 –0.090
+0.263 +0.048
0.084 – 0.353
0.062
Bucket
160
–0.043 –0.106
+0.256 +0.039
0.082 – 0.362
0.062
Boom
115
–0.036 –0.090
+0.025 0
0.036 – 0.115
1.5
Arm
110
–0.036 –0.090
+0.457 +0.370
0.406 – 0.547
1.5
Bucket
140
–0.043 –0.106
+0.025 0
0.043 – 0.131
1.5
Boom
130
–0.043 –0.106
+0.025 0
0.043 – 0.131
1.5
Arm
110
–0.036 –0.090
+0.457 +0.370
0.406 – 0.547
1.5
Bucket
140
–0.043 –0.106
+0.025 0
0.043 – 0.131
1.5
Name of cylinder
Standard size
Boom
Replace bushing
Replace pin, bushing
10-113
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC CYLINDER
LOADING SHOVEL SPECIFICATION PC750-7 BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-113-1 (3)
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC CYLINDER
BOTTOM DUMP CYLINDER
Unit: mm No.
1
2
3
Check item
Clearance between piston rod and bushing
Clearance between piston rod support shaft and bushing
Clearance between cylinder bottom support shaft and bushing
PC750, 800-7
Criteria Tolerance
Remedy
Shaft
Hole
Standard clearance
140
–0.043 –0.106
+0.256 +0.039
0.082 – 0.362
0.662
Arm
160
–0.043 –0.106
+0.256 +0.039
0.082 – 0.362
0.662
Bucket
130
–0.043 –0.106
+0.256 +0.040
0.082 – 0.362
0.662
Bottom dump
90
–0.036 –0.090
+0.257 +0.048
0.084 – 0.347
0.647
Boom
115
–0.036 –0.090
+0.025 0
0.036 – 0.115
1.5
Arm
140
–0.043 –0.106
+0.025 0
0.043 – 0.131
1.5
Bucket
115
–0.036 –0.090
0 –0.020
0.016 – 0.090
1.5
Bottom dump
90
–0.036 –0.090
+0.457 +0.370
0.406 – 0.547
1.5
Boom
130
–0.043 –0.106
+0.025 0
0.043 – 0.131
1.5
Arm
140
–0.043 –0.106
+0.025 0
0.043 – 0.131
1.5
Bucket
115
–0.036 –0.090
0 –0.020
0.016 – 0.090
1.5
Bottom dump
90
–0.036 –0.090
+0.457 +0.370
0.406 – 0.547
1.5
Name of cylinder
Standard size
Boom
Clearance limit
Replace bushing
Replace pin, bushing
10-113-2 (3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
WORK EQUIPMENT PC750-7 PC750LC-7
10-114
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm No.
Check item
1
Clearance between bushing and mounting pin of boom and revolving frame
Criteria Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
140
–0.043 –0.106
+0.542 +0.442
0.485 – 0.648
1.5
Standard size
2
Clearance between bushing and mounting pin of boom and arm
140
–0.043 –0.106
+0.542 +0.442
0.485 – 0.648
1.5
3
Clearance between bushing and mounting pin of arm and link
115
–0.036 –0.090
+0.351 +0.271
0.307 – 0.441
1.5
4
Clearance between bushing and mounting pin of arm and bucket
130
–0.043 –0.106
+0.482 +0.392
0.435 – 0.588
1.5
5
Clearance between bushing and mounting pin of link and link
110
–0.036 –0.090
+0.351 +0.271
0.307 – 0.441
1.5
6
Clearance between bushing and mounting pin of link and bucket
115
–0.036 –0.090
+0.351 +0.271
0.307 – 0.441
1.5
7
Bucket clearance
PC750, 800-7
0.5 – 1.0
Replace
Adjust shims
10-115
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
PC750SE-7 PC800, 800SE-7
10-116
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm No.
Check item
1
Clearance between bushing and mounting pin of boom and revolving frame
Criteria Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
140
–0.043 –0.106
+0.542 +0.442
0.485 – 0.648
1.5
Standard size
2
Clearance between bushing and mounting pin of boom and arm
140
–0.043 –0.106
+0.542 +0.442
0.485 – 0.648
1.5
3
Clearance between bushing and mounting pin of arm and link
115
–0.036 –0.090
+0.351 +0.271
0.307 – 0.441
1.5
4
Clearance between bushing and mounting pin of arm and bucket
130
–0.043 –0.106
+0.482 +0.392
0.435 – 0.588
1.5
PC800
110
–0.036 –0.090
+0.351 +0.271
0.307 – 0.441
1.5
5
Clearance between bushing and mounting pin of link and link
PC750SE PC800SE
140
–0.043 –0.106
+0.397 +0.312
0.313 – 0.467
1.5
6
Clearance between bushing and mounting pin of link and bucket
115
–0.036 –0.090
+0.351 +0.271
0.307 – 0.441
1.5
7
Bucket clearance
PC750, 800-7
Replace
0.5 – 1.0
Adjust shims
10-117
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
LOADING SHOVEL SPECIFICATION PC750-7
10-117-1 (3)
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm No.
Check item
1
Clearance between boomrevolving frame mounting pin and bushing
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
140
–0.043 –0.106
+0.542 +0.442
0.485 – 0.648
1.5
2
Clearance between boomarm mounting pin and bushing
140
–0.043 –0.106
+0.542 +0.442
0.485 – 0.648
1.5
3
Clearance between armbucket mounting pin and bushing
140
–0.043 –0.106
+0.523 +0.460
0.503 – 0.629
1.5
4
Clearance between bucket cylinder-bucket mounting pin and bushing
115
–0.036 –0.090
+0.457 +0.370
0.406 – 0.547
1.5
5
Clearance between front bucket-rear bucket mounting pin and bushing
95
–0.036 –0.090
+0.344 0
0.308 – 0.434
1.5
PC750, 800-7
Replace
10-117-2 (3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
DIMENSIONS OF WORK EQUIPMENT
DIMENSIONS OF WORK EQUIPMENT 1. ARM
10-118
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
DIMENSIONS OF WORK EQUIPMENT
Unit: mm Model
PC800-7
PC750SE-7 PC800SE-7
PC800SE-7
with 3.6 m arm
with 4.6 m arm
with 5.6 m arm
with 3.6 m heavy-duty arm
with 2.9 m short arm
with 3.6 m arm
1
ø115
ø115
ø115
ø110
ø110
ø110
2
100
100
100
129
129
129
3
531
531
531
531
531
531
4
ø140
ø140
ø140
ø140
ø140
ø140
5
580
620
639
663
750
663
6
397
467
530
329
401
329
7
1,332
1,389
1,328
925
916
925
8
3,578
4,569
5,575
3,585
2,917
3,585
9
3,675
3,688
3,673
4,011
3,580
4,011
10
585
570
585
585
500
585
11
950
950
950
1,035
840
1,035
12
740
740
740
865
640
865
13
756
756
756
765
670
765
14
2,237
2,237
2,237
2,237
2,233
2,237
15
ø115
ø115
ø115
ø115
ø115
ø115
16
519
519
519
519
519
519
17
ø130
ø130
ø130
ø130
ø130
ø130
Arm as individual part
519
519
519
519
519
519
When pressfitting bushing
535
535
535
535
535
535
Min.
2,380
2,380
2,380
2,590
2,490
2,590
Max.
3,990
3,990
3,990
4,410
3,910
4,410
No.
18
PC750-7
19
PC750, 800-7
10-119
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
DIMENSIONS OF WORK EQUIPMENT
2. BUCKET
10-120
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
DIMENSIONS OF WORK EQUIPMENT
Unit: mm Model
PC750-7
PC750SE-7 PC800SE-7
PC800-7
PC800SE-7
with 2.8 m3 bucket
with 3.1 m3 bucket
with 3.4 m3 bucket
with 4.0 m3 bucket
with 4.3 m3 bucket
with 4.5 m3 bucket
with 4.0 m3 Light-load bucket
1
749
749
747
667
667
667
747
2
104
104
164
61
61
61
164
3
98°
98°
102°
95°
95°
95°
102°
4
756
756
765
670
670
670
765
5
2,218
2,218
2,218
2,211
2,211
2,211
2,211
6
292
292
292
315
315
315
315
a
ø130
ø130
ø130
ø130
ø130
ø130
ø130
b
ø115
ø115
ø115
ø115
ø115
ø115
ø115
8
520
520
520
520
520
520
520
9
80.5
80.5
80.5
80.5
80.5
80.5
80.5
10
88.5
88.5
88.5
88.5
88.5
88.5
88.5
11
ø208
ø208
ø238
ø208
ø208
ø208
ø238
12
ø255
ø255
ø255
ø255
ø255
ø255
ø255
13
ø275
ø275
ø275
ø275
ø275
ø275
ø275
14
217
217
253
135
135
135
260
15
175
175
175
181
181
181
181
16
157.5
157.5
157.5
157.5
157.5
157.5
157.5
17
125
125
140
125
125
125
140
18
559.5
559.5
559.5
559.5
559.5
559.5
559.5
19
79
79
79
79
79
79
79
No.
7
PC750, 800-7
10-121
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
AIR CONDITIONER
AIR CONDITIONER AIR CONDITIONER PIPING STD CAB SPECIFICATION
1. 2. 3. 4. 5. 6. 7. 8.
Duct Condenser Air conditioner compressor Hot water return piping Hot water pickup piping Refrigerant piping Receiver tank Air conditioner unit
10-122
A. Fresh air B. Recirculated air C. Hot air/cold air
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE CONTROL
ENGINE CONTROL
1. 2. 3. 4. 5. 6. 7.
Battery Battery relay Starting switch Fuel control dial Supply pump Starting motor Engine controller
PC750, 800-7
Function • The engine can be started and stopped simply by using starting switch (3). • A dial-type engine control is used to control the engine speed. Engine controller (7) receives the control signal from fuel control dial (4), sends a drive signal to supply pump (5), and controls the angle of the governor lever in the fuel injection pump.
10-123
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE CONTROL
1. Operation of system Starting engine • When the starting switch is turned to the START position, the starting signal flows to the starting motor, and the starting motor turns to start the engine. When this happens, the engine controller checks the signal from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.
Engine speed control • The fuel control dial sends signal voltages to the engine controller according to its angle. The engine controller sends drive signals to the supply pump according to the signal voltages received from the fuel control dial and controls the fuel injection pump to control the engine speed.
Stopping engine • When the engine controller detects that the starting switch is at the STOP position, it cuts the signal to the supply pump drive solenoid to stop the engine.
10-124
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE CONTROL
2. Components of system Fuel control dial 1. 2. 3. 4. 5. 6.
Knob Dial Spring Ball Potentiometer Connector
Function • The fuel control dial is installed at the bottom of the monitor panel. A potentiometer is installed under the knob, and when the knob is turned, it rotates the potentiometer shaft. When the shaft rotates, the resistance of the variable resistor inside the potentiometer changes, and the desired throttle signal is sent to the engine controller. • The hatched area in the graph on the right is the abnormality detection area and the engine speed is set at low idling.
PC750, 800-7
10-125
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE CONTROL
3. Engine controller
10-126
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE CONTROL
Input and output signals CN1 [CN-E11] Pin No.
CN2 [CN-E12] Signal name
Input/ Output
CN1-1 POWER (+24V constant) CN1-2 POWER (+24V constant) CN1-3 Model selection 1 CN1-4 GND CN1-5 NC CN1-6 NC
CN1-11 NC CN1-12 NC CN1-13 Key switch (ACC) CN1-14 NC
Signal name
Input Input Output
CN2-3 NC CN2-4 RS232C_1RX
CN2-7 NC CN2-8 NC Input Input Output
CN2-9 Sensor 5V power supply 2 CN2-10 Fuel control dial
Input
CN2-15 G_SHIELD (GND) CN2-16 Ne_SHIELD (GND)
CN1-16 Memory clear CN1-17 Model selection 3
Input Input
CN2-17 Fuel temperature sensor CN2-18 NC
CN1-18 NC CN1-19 Key switch (ACC)
Output Input
CN1-20 Starting switch (C)
Input
Engine oil pressure switch (For low CN1-21 pressure)
Input
CN1-22 Auto deceleration signal
Input
CN1-23 Model selection 2 CN1-24 NC
Input Output
Input Input Output Input
CN2-11 S_NET_SHIELD GND CN2-12 CAN_SHIELD CN2-13 NC CN2-14 RS232C_1TX
Engine oil pressure switch (For high pressure)
Input Input
CN2-5 NC CN2-6 NC
Input Input
CN1-15
Input/ Output
CN2-1 GND CN2-2 NC
CN1-7 GND CN1-8 GND CN1-9 NC CN1-10 GND
Pin No.
Output Output
Input Input
CN2-19 Sensor 5V power supply 1 CN2-20 Boost pressure sensor
Output Input
CN2-21 S_NET (+)
Input/ Output
CN2-22 CAN0_L
Input/ Output
CN2-23 NC CN2-24 FWE_switch
Input
CN2-25 G pulse (–) CN2-26 Ne pulse (–)
Input Input
CN2-27 Water temperature sensor (High) CN2-28 NC
Input Input
CN2-29 Analog GND CN2-30 NC
Input
CN2-31 S_NET (+)
Input/ Output
CN2-32 CAN0_H
Input/ Output
CN2-33 NC CN2-34 GND (232C_GND)
PC750, 800-7
CN2-35 G pulse (+) CN2-36 Ne pulse (+)
Input Input
CN2-37 Water temperature sensor (Low) CN2-38 NC
Input Input
CN2-39 Analog GND CN2-40 Common rail pressure sensor
Input
10-127
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE CONTROL
CN3 [CN-E13] Pin No.
Signal name
Input/ Output
CN3-1 Power supply for power CN3-2 Power supply for power CN3-3 NC CN3-4 NC CN3-5 Injector #3 (+)
Output
CN3-6 Injector #2 (+) CN3-7 NC
Output Input
CN3-8 Output mode selection 1 (Test mode) CN3-9 Lever neutral flag (Test mode)
Input Input
CN3-10 Engine rotation pulse output CN3-11 Power GND
Output Input
CN3-12 Supply pump 1 (+) CN3-13 Supply pump 2 (+)
Output Output
CN3-14 Injector #1 (+) CN3-15 Injector #3 (–)
Output Output
CN3-16 Injector #2 (–) CN3-17 NC
Output Input
CN3-18 Output mode selection 2 (Test mode) CN3-19 NC
Input Input
CN3-20 Q command output CN3-21 Power supply for power
Output
CN3-22 Supply pump 1 (–) CN3-23 Supply pump 2 (–)
Output Output
CN3-24 Injector #1 (–) CN3-25 Injector #6 (+)
Output Output
CN3-26 Injector #4 (+) CN3-27 NC
Output Output
CN3-28 Auto deceleration flag (Test mode) CN3-29 NC
Input Input
CN3-30 GND CN3-31 Power GND CN3-32 Power GND CN3-33 Injector #5 (–)
Output
CN3-34 Injector #5 (+) CN3-35 Injector #6 (–)
Output Output
CN3-36 Injector #4 (–) CN3-37 NC
Output Output
CN3-38 Auto deceleration control (Test mode) CN3-39 NC
Input Input
CN3-40 GND
10-128
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
MACHINE CONTROL SYSTEM CONTROL FUNCTIONS
PC750, 800-7
10-129
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
MACHINE CONTROL SYSTEM DIAGRAM
10-130
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
1. Auto deceleration system
Function • If all the control levers are at neutral when waiting for work or waiting for a dump truck, the engine speed is automatically reduced to a midrange speed to reduce fuel consumption and noise. • If any lever is operated, the engine speed returns immediately to the set speed.
PC750, 800-7
10-131
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
Operation 1. When auto-deceleration switch is turned ON Control levers at neutral • If the engine is running at above the deceleration actuation speed (approx. 1400 rpm), and all the control levers are returned to neutral, the engine speed drops immediately to approx. 100 rpm below the set speed to the No. 1 deceleration position. • If another 4 seconds passes, the engine speed is reduced to the No. 2 deceleration position (approx. 1400 rpm), and is kept at that speed until a lever is operated.
When control lever is operated • If any control lever is operated when the engine speed is at No. 2 deceleration, the engine speed will immediately rise to the speed set by the fuel control dial.
2. When auto-deceleration switch is turned OFF Control lever at neutral • If the engine is running at a speed above 1,880 rpm and all the control levers are returned to neutral, the engine speed drops to approx. 1,880 rpm after 4 seconds and is kept at that speed until a lever is operated.
10-132
When control lever is operated • If any control lever is operated under the condition shown at left (after the engine speed drops to approx. 1,880 rpm), the engine speed will immediately rise to the speed set by the fuel control dial.
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
2. Electronic OLSS function Pump control system
• •
•
Interconnected control of all pumps is carried out by one TVC valve. A mode: Total horsepower control by engine speed sensing E mode: Total horsepower control by engine speed sensing Emergency pump drive circuit: Constant torque control
PC750, 800-7
10-133
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
1) Control method in each mode A, E mode
•
Matching point in A, E mode: Rated output point Model Mode
•
•
•
PC750-7 PC800-7
A
338 kW/1,800 rpm {454 HP/1,800 rpm}
E
291 kW/1,700 rpm {390 HP/1,700 rpm}
When the load on the pump rises and the pressure rises, the engine speed goes down. At this time, the pump discharge is reduced and the engine speed is set about the rated output point. If the pressure lowers, the pump discharge is increased until the engine speed is set about the rated output point. By repeating this control, the engine can always be used at near the rated output point. Compared with the A mode, which provides the maximum output, the E mode lowers the engine output to provide matching at a point which gives better fuel consumption efficiency than the A mode. The A mode uses the CO cancel so it can generate a greater discharge of oil than in the E mode at high pressure.
10-134
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
2) Cut-off function • If the load during operation increase and the pump discharge pressure rises to near the relief pressure, the main pump cut-off valve is actuated to reduce the relief loss.
3) Cut-off cancel function • The cut-off cancel function acts to stop the operation of the cut-off function in order to ensure the pump flow when close to the relief pressure, thereby preventing any drop in speed.
•
Cut-off function and actuation of each switch Switch Function Cut-off function
PC750, 800-7
Working mode switch
Travel lever
Heavy lift
A
E
ON
OFF
ON
OFF
Cancel
Actuated
Cancel
Actuated
Cancel
Actuated
10-135
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
3. Heavy lift function
Outline • This function increases the boom lifting power by approx. 10%. • It can be actuated only when the boom RAISE is being actuated independently. If the arm IN or bucket CURL are operated at the same time, the heavy-lift function is automatically canceled.
10-136
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
Operation Heavy-lift switch OFF
ON
Lever operation Boom RAISE
Arm IN or bucket CURL
Heavy-lift solenoid valve
Main relief valve set pressure
CO valve switch
Boom lifting force
Operated
—
De-energized
31.4 MPa {320 kg/cm2}
Actuated
Normal
Neutral
Energized
34.3 MPa {350 kg/cm2}
Canceled
10% up
Operated Operated
If the arm IN or bucket CURL are operated during boom RAISE operations, this function is automatically canceled, and the condition becomes the same as when the switch is turned OFF.
Normal
a Heavy-lift solenoid valve For details of the structure and function, see SOLENOID VALVE. a CO valve For details of the structure and function, see NO. 1 PUMP ASSEMBLY. a Main relief valve For details of the structure and function, see L.H. 5-SPOOL CONTROL VALVE.
PC750, 800-7
10-137
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
4. 2-stage boom pushing force selector function
Outline • This function switches the pushing force of the boom. It is aimed to provide both increased digging efficiency by reducing the digging resistance of the boom, and increased ease of operation by increasing the thrusting force for excavation, digging square holes, carrying out twist turns, or escaping from soft ground.
10-138
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
Operation • This function acts to change the set pressure of the safety valve at the boom cylinder end of the R.H. 4-spool control valve boom Lo in 2 ways: to low pressure (14.7 MPa {150 kg/cm2}) and high pressure (33.3 MPa {340 kg/cm2}. Mode
Boom pushing force (low mode)
Boom pushing force (high mode)
Machine push-up switch
Machine push-up solenoid valve
Energized
De-energized
Safety valve set pressure
Effect
14.7 MPa {150 kg/cm2}
By reducing the boom pushing force, it is made easier for the boom to escape automatically in the RAISE direction and to reduce the number of times that the boom is operated. At the same time it also makes the digging operation smoother.
33.3 MPa {340 kg/cm2}
By increasing the thrust force for boom LOWER, the ease of operation is improved for excavation, digging square holes, carrying out twist turns, or escaping from soft ground.
a Machine push-up solenoid valve For details of the structure and function, see SOLENOID VALVE. a Boom safety valve For details of the structure and function, see R.H. 4-SPOOL CONTROL VALVE.
PC750, 800-7
10-139
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
5. Swing control system
Function • The system is provided with a swing lock and swing holding brake function.
10-140
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Swing lock, swing holding brake function • The swing lock (manual) can be locked at any desired position, and the swing lock and swing holding brake (automatic) are interconnected with the swing, so they prevent any hydraulic drift after the swing is stopped.
MACHINE CONTROL SYSTEM
a Swing brake solenoid valve For details of the structure and function, see SOLENOID VALVE. a Swing motor For details of the structure and function, see SWING MOTOR.
Actuation Mode
Swing lock switch
Swing lock monitor
Swing brake solenoid valve
Actuation When swing and work equipment levers are placed at neutral, swing brake is applied after approx. 10 sec; when any swing or work equipment lever is operated, brake is canceled and swing can be operated freely.
Swing holding brake
OFF
OFF
See diagram on right
Swing brake
ON
ON
De-energized
Operation of swing lock prolix switch • If any abnormality should occur in the controller, and the swing holding brake is not actuated normally and the swing cannot be operated, the swing lock prolix switch can be operated to cancel the swing lock and allow the swing to be operated. a Even when the swing lock prolix switch is turned ON, the swing lock switch stays ON and the swing brake is not canceled. a When the swing brake is canceled, the swing has only a hydraulic brake operated by the safety valve, so if the swing is stopped on a slope, there may be hydraulic drift.
PC750, 800-7
Swing lock is actuated and swing is held in position. Even when swing lever is operated, swing lock is not canceled and swing does not move.
Swing lock prolix switch
ON (when controller is abnormal)
OFF (when controller is normal)
Swing lock switch
ON
OFF
ON
OFF
Swing brake
Swing lock applied
Swing lock canceled
Swing lock applied
Swing holding brake applied
10-141
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
6. Engine automatic warming-up, overheat prevention function, turbo protect function, split injection function
Function • If the water temperature is low, this automatically raises the engine speed to warm up the engine after it is started. In addition, if the water temperature rises too high during operations, it reduces the load of the pump to prevent overheating. • To protect the turbocharger bearing during cold weather, the engine speed is kept below the fixed speed when the engine is started. In addition, to improve the starting ability, a small amount of fuel is injected two or more times before the main injection.
10-142
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
1) Engine automatic warming-up function • After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm up the engine.
2) Engine overheat prevention function • This function protects the engine by lowering the pump load and engine speed to prevent overheating when the engine coolant temperature has risen too high. • This system is actuated at 105°C and above.
PC750, 800-7
10-143
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
3) Turbo protection function Function to protect turbocharger bearing during cold weather by keeping engine speed below fixed speed when engine is started. Actuation condition Engine water temperature
Turbo protect time (sec)
More than +10°C
0
+10°C to –10°C
Gradually changes between 0 and 5
Less than –10°C
5
Engine speed: 1000 rpm Even if the fuel control dial is operated during the above time, the engine speed will not change. After the set time passes, the operation moves to the automatic warming up function in Step 1). 4) Split injection function To improve the ease of starting in cold weather, a small amount of fuel is injected two or more times within the set time after calculating in the table below before starting the main injection. As a result, the lower idling speed during this time becomes slightly higher. Actuation condition Water temperature
Split injection time (sec)
More than 20°C
0
20°C to –30°C
0 – 15
Less than –30°C
15
10-144
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
7. Travel speed selection function
This is an automatic gear shift function in which the travel pressure (self pressure) switches the swash plate angle of the travel motor. • If the machine is traveling at high speed with the travel speed switch at Hi and the load increases, such as when traveling up a steep hill, if the travel pressure goes above 22.6 MPa {230 kg/cm2}, the self pressure switches to low speed. The machine continues to travel at low speed and when it comes to flat ground and the load is reduced, if the travel pressure goes below 22.6 MPa {230 kg/cm2}, the travel speed is automatically switched to high speed. Travel speed switch
Travel speed solenoid valve
Travel motor swash plate angle
Travel speed
Lo
De-energized
Max.
Low speed (max 2.8 km/h)
Hi
Energized
Max. Min
PC750, 800-7
Remarks Suitable for traveling downhill or on rough ground
Low speed (2.8 km/h) Suitable for use when moving High speed (4.2 km/h) long distances
10-145
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
Outline • To maintain the drawbar pull when traveling, the cut-off is canceled and the main relief pressure is raised from 31.4 MPa {320 kg/cm2} to 34.3 MPa {350 kg/cm2}. Operation Pressure increase solenoid valve
Main relief valve set pressure
Cut-off cancel solenoid valve
CO valve
When traveling
Energized
34.3 MPa {350 kg/cm2}
Energized
Canceled
When not traveling
De-energized
31.4 MPa {320 kg/cm2}
De-energized
Actuated
10-146
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
8. Boom shockless control function This function improves safety by preventing spillage of the load from the bucket and by reducing the shock when the boom is stopped, thereby reducing operator fatigue.
Actuation
•
•
Boom shockless switch
Cancel solenoid valve
Boom shockless control
Remarks
ON (Contacts open)
De-energized
ON
Suitable for normal operations
OFF (Contacts closed)
Energized
Canceled
Suitable for compacting or skeleton work
If the boom is raised, the pilot pressure from the PPC valve is generated in line A. When this happens, the pressure in line A passes through check valve (2) and pushes the spool of the main valve in the direction of the arrow. The pilot oil at the left end of the spool passes through line B and the PPC valve, and returns to the tank. However, when this happens, check valve (4) is being pushed open by the pressure in line A, so it also allows the oil to pass in the opposite direction. For this reason, the boom can be raised without any delay in response. In this condition, if the boom RAISE operation is stopped, the spool of the main valve moves in the opposite direction to the arrow and drains the oil from line A. However, the action of check valve (2) means that the oil must pass through orifice (1). As a result, the spool returns slowly to the neutral position to prevent any shock.
PC750, 800-7
10-147
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
9. Straight-travel function
Outline • When the travel is operated at the same time as the boom, arm, or bucket, the pressure oil flowing to the left and right travel circuits is divided and sent to the boom, arm, or bucket circuit. If the oil in one travel circuit is divided off, the amount of oil supplied to the travel motor will be less than in the travel circuit which is not divided, so the drop in the supply of oil to the travel motor will cause the machine to deviate.
10-148
•
To prevent this, the straight-travel valve is switched to interconnect the left and right travel circuits. This ensures that the amount of oil supplied to the left and right travel motors is equal, so the left and right travel motors both rotate at the same speed, and this prevents any travel deviation.
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
Operation Left and right travel levers
Work equipment control lever, swing lever
Straight-travel solenoid valve
Straight-travel valve
Neutral
De-energized
Not actuated
Left and right travel motor circuits independent
Operated
Energized
Actuated
Left and right travel motor circuits assist
Operation
PC750, 800-7
Remarks
10-149
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
10. Swing priority function •
There is a swing priority mode switch on the monitor panel. By turning this switch ON/OFF it is possible to change the matching of the boom RAISE and swing. This divides the flow to provide a swing speed which matches the swing angle, thereby enabling the operator to carry out compound operations easily.
Loading a dump truck on the same ground
Swing priority mode OFF:
{ Swinging by 90º and loading a dump truck
Swing priority mode ON:
{ Loading a dump truck from a bench
10-150
Swinging by 180º and loading a dump truck
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
•
MACHINE CONTROL SYSTEM
The matching between the boom RAISE and swing is carried out by changing the signal to the boom circuit throttle valve. Solenoid
Swing priority selector valve
Swing priority mode OFF (standard)
OFF (de-energized)
ON
Swing priority mode ON (swing priority)
ON (energized)
OFF
PC750, 800-7
10-151
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
11. Swing assurance function •
During compound operations with the arm and swing or with the bucket and swing, the throttle valves in the arm and bucket circuit ensure the flow of oil to the swing circuit in order to assure ease of compound operations.
Operation • If the swing PPC pressure goes above 1.5 MPa {15 kg/cm2} (the control lever is operated approximately half or more), the swing assurance selector valve is actuated and the swing drive pressure locks the pilot check valve of the 5-spool valve arm and bucket throttle valves. • In this condition, the circuits are in parallel, so the oil from the 5-spool valve flowing to the arm or bucket is throttled by the throttle valve, so the swing drive pressure rises. In this way, the swing drive is assured.
10-152
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
12. Components of system 1) Engine speed sensor
1. 2. 3. 4. 5.
Wire Magnet Terminal Housing Connector
Function • The engine speed sensor is installed to the ring gear portion of the engine flywheel. It counts electrically the number of gear teeth that pass in front of the sensor, and sends the results to the engine controller and pump controller. • This detection is carried out by a magnet, and an electric current is generated every time the gear tooth passes in front of the magnet.
2) PPC hydraulic switch 1. Plug 2. Switch 3. Connector
Specifications Composition of points: N.O. points Actuation (ON) pressure: 0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2} Reset (OFF) pressure: 0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm2} Function • There are 12 switches installed to the PPC block. The operating condition of each actuator is detected from the PPC pressure, and this is sent to the engine controller and pump controller.
PC750, 800-7
10-153
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
3) TVC prolix resistor
1. Resistor 2. Connector
Specification Resistance: 20 z
Function • This resistor acts to allow a suitable current to flow to the TVC solenoid when the TVC prolix switch is ON. • No current flows when the TVC prolix switch is OFF.
4) Fuel control dial, engine controller a See ENGINE CONTROL. 5) Monitor panel a See MONITOR SYSTEM. 6) TVC valve a See HYDRAULIC PUMP.
10-154
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
7) Pump controller
PC750, 800-7
10-155
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
Input and output signals CN1 [CN-C01] Pin No.
CN2 [CN-C02] Signal name
Input/ Output
Pin No.
Signal name
Input/ Output
CN1-1 NC CN1-2 R pump pressure sensor
Input Input
CN2-1 NC CN2-2 Swing prolix switch
CN1-3 NC CN1-4 NC
Input
CN2-3 NC CN2-4 RS232C-R × D
Input Input
CN1-5 Auto grease controller trouble CN1-6 NC
Input Input
CN2-5 Overload sensor (ON/OFF) CN2-6 NC
Input Input
CN1-7 NC CN1-8 F pump pressure sensor
Input Input
CN2-7 Model selection 4 (ATT) CN2-8 NC
Input Output
CN1-9 NC CN1-10 GND (SIG)
Input
CN2-9 NC CN2-10 NC
Output Input
CN1-11 (Knob switch) CN1-12 NC
Input Input
CN2-11 NC CN2-12 CAN_SH
Output
CN1-13 NC CN1-14 NC
Input Input
CN2-13 NC CN2-14 RS232C-T × D
Input Output
CN1-15 NC CN1-16 NC
Input Output
CN2-15 NC CN2-16 Left travel pressure switch
Output Input
Input Input
CN1-17 Key switch (Terminal C) CN1-18 NC
Input Input
CN2-17 Model selection 3 CN2-18 NC
Input Output
CN1-19 NC CN1-20 NC
Input Input
CN2-19 Auto deceleration CN2-20 NC
Output Input
CN2-21 S_NET
Input/ Output
CN2-22 CAN0_L
Input/ Output
CN2-23 NC
Input/ Output
CN1-21 NC CN1-22 Sensor power supply (+5V) CN1-23 Key switch (Terminal Acc) CN1-24 Stop light switch
10-156
Output Input Input
CN2-24 Boot program switch CN2-25 Horn switch
Input Input
CN2-26 NC CN2-27 Model selection 2
Input Input
CN2-28 NC CN2-29 NC
Input
CN2-30 NC CN2-31 GND (S_NET_GND)
Input
CN2-32 CAN0_H
Input/ Output
CN2-33 NC
Input/ Output
CN2-34 GND (RS232C) CN2-35 Service valve pressure switch
Input
CN2-36 NC CN2-37 Model selection 1
Input Input
CN2-38 Swing lock switch CN2-39 Engine speed sensor (GND)
Input
CN2-40 Engine speed sensor
Input
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MACHINE CONTROL SYSTEM
CN3 [CN-C03] Pin No.
Signal name
Input/ Output
CN3-1 VB (Controller PWR) CN3-2 VIS (Solenoid PWR)
Input Input
CN3-3 TVC solenoid (–)
Input
CN3-4 Battery relay drive CN3-5 Step light power holding relay
Output Output
CN3-6 NC CN3-7 Straight travel solenoid
Output Output
CN3-8 Travel alarm CN3-9 Bucket CURL pressure switch
Output Input
CN3-10 Boom RAISE pressure switch CN3-11 VB (Controller PWR)
Input Input
CN3-12 VIS (Solenoid PWR) CN3-13 NC
Input Input
CN3-14 VB (Controller PWR) CN3-15 Step light drive relay
Input Output
CN3-16 TVC solenoid (+) CN3-17 CO cancel solenoid
Output Output
CN3-18 NC CN3-19 Bucket DUMP pressure switch
Output Input
CN3-20 Boom LOWER pressure switch CN3-21 GND (Controller GND)
Input Input
CN3-22 NC CN3-23 NC
Input Input
CN3-24 VB (Controller PWR) CN3-25 Flash light driver relay
Input Output
CN3-26 NC CN3-27 Travel Hi/Lo selector solenoid
Output Output
CN3-28 2-stage relief solenoid CN3-29 Swing pressure switch
Output Input
CN3-30 Arm IN pressure switch CN3-31 GND (Controller GND)
Input Input
CN3-32 GND (Controller GND) CN3-33 GND (Controller GND)
Input Input
CN3-34 NC CN3-35 NC
Output
CN3-36 NC CN3-37 Swing holding brake solenoid
Output Output
CN3-38 Swing priority solenoid CN3-39 Right travel pressure switch
Output Input
CN3-40 Arm OUT pressure switch
PC750, 800-7
Input
10-157
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
MONITOR SYSTEM
•
•
The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It processes and immediately displays the obtained information on the panel notifying the operator of the condition of the machine. The panel is roughly divided as follows. 1. Monitor section to output alarms when the machine has troubles 2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.) The monitor panel also has various mode selector switches and functions to operate the machine control system.
10-158
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
1. Monitor panel
Outline • The monitor panel has the functions to display various items and the functions to select modes and electric parts. The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information. The monitor display unit consists of LCD (Liquid Crystal Display). The switches are flat sheet switches.
PC750, 800-7
10-159
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
Input and output signals CN1 Pin No.
Signal name
1 2
Key switch (Battery) Key switch (Battery)
3 4
Washer motor output Key switch (Terminal C)
5 6
Wiper contact W (Lower wiper contact P) GND
7 8
GND VB + (24 V)
Input/ output
CN3 Pin No.
Input Input
1 2
NC NC
Input Input
Output Input
3 4
NC NC
Input Input
Input
5 6
NC NC
Input Input
7 8
NC NC
Input Input
9
NC
Input/ output
10 NC
Input/ output
11 NC 12 NC
Input Input
13 NC 14 CAN (Shield)
Input
15 CAN (+) 16 CAN (–)
Input Input
Input
9 Wiper motor (+) 10 Wiper motor (–)
Output Output
11 NC 12 Wiper contact P (Upper wiper contact P)
Input Input
CN2 Pin No.
Signal name
Input/ output
1
NC
Input
2 3
Fuel Radiator water level
Input Input
4 5
NC Air cleaner clogging sensor
Input Input
6 7
NC NC
Input Input
8
Engine oil level sensor
Input
Network (S-NET signal)
Input/ output
10 Network (S-NET signal)
Input/ output
9
11 Charge level
Input
12 Hydraulic oil temperature (Analog) 13 GND (For analog signal)
Input
14 Personal code relay (Lo) 15 Window limit switch
Input Input
16 Buzzer cancel 17 Swing lock
Input Input
18 Preheating 19 Light switch
Input Input
Signal name
Input/ output
20 Network (S-NET GND)
10-160
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
MONITOR CONTROL, DISPLAY PORTION MONITOR PORTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Wiper motor Preheating monitor Swing lock monitor Engine water temperature monitor Hydraulic oil temperature gauge Engine water temperature gauge Working mode monitor Service meter Travel speed monitor Fuel gauge
PC750, 800-7
11. 12. 13. 14. 15. 16. 17. 18. 19.
Fuel level monitor Hydraulic oil temperature monitor Auto-deceleration monitor Radiator water level caution Battery charge caution Engine oil pressure caution Engine oil level caution Air cleaner clogging Maintenance time warning caution
10-161 (3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
MONITOR ITEMS AND DISPLAY Symbol
Display item
Swing lock
Preheating
Display method
Swing lock switch
Swing holding brake release switch
Swing lock monitor
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
Flashes
ON
ON
ON
Continuous set time
Preheating monitor status
Up to 30 sec.
ON
From 30 sec. to 40 sec.
Flashes
More than 40 sec.
OFF
Engine water temperature Hydraulic oil temperature
See gauge display on the next page
Fuel level
10-162
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Gauge
Engine water temperature (°C)
Hydraulic oil temperature (°C)
Fuel level (l)
PC750, 800-7
MONITOR SYSTEM
Range
Temperature, volume
Indicator
A1
105
Red
A2
102
Red
A3
100
Green
A4
80
Green
A5
60
Green
A6
30
White
B1
105
Red
B2
102
Red
B3
100
Green
B4
80
Green
B5
40
Green
B6
20
White
C1
524
Green
C2
382
Green
C3
249
Green
C4
138
Green
C5
101
Green
C6
84
Red
Buzzer sound
10-163
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
Checks before starting (caution lamps all light up), when maintenance interval is exceeded. If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are displayed.
Symbol
Display item
Check before starting item
When engine is stopped
When engine is running
Engine oil pressure
q
—
When abnormal, lights up and buzzer sounds
Battery charge
q
—
Lights up when abnormal
Radiator water level
q
Lights up when abnormal
When abnormal, lights up and buzzer sounds
Engine oil level
q
Lights up when abnormal
—
Air cleaner clogging
q
—
Lights up when abnormal
Maintenance
Lights up when there is a warning. Lights up for only 30 sec. after key is turned ON, then goes out.
The problems that have occurred are displayed in order from the left. When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is displayed. Condition of hydraulic oil
Color of symbol
Low temperature (below B6 or equivalent)
Black on white background
Normal (B6 – B2)
No display
High temperature (above B2)
White on red letters
10-164 (3)
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Display category
Symbol
Display item
Wiper
MONITOR SYSTEM
Display range
INT
ON
Display method
OFF
Displays set condition
Working mode
Displays set mode
Travel speed
Displays set speed
Monitor
Auto-deceleration
Service meter
PC750, 800-7
Service meter indicator
ON
OFF
When service meter is working
Displays actuation status
Lights up when service meter is working
10-165
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
SWITCHES
1. 2. 3. 4. 5. 6. 7. 8.
Working mode selector switch Display brightness, contrast adjustment switch Control switch Window washer switch Wiper switch Maintenance switch Travel speed selector switch Auto-deceleration switch
10-166
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
•
•
Working mode selector switch The condition of the machine changes according to the switch that is pressed (Shown in the figure at right). It is possible to check the condition on the working mode monitor display. The relationship between each working mode and the monitor display is shown in the table on the right.
Switch that is pressed
Display
Working mode status after setting
[A]
A
A mode (default)
[E]
E
E mode Heavy-lift mode
Maintenance switch Check the condition of the maintenance items. (For details, see MAINTENANCE FUNCTION.)
•
Auto-deceleration switch Each time the auto-deceleration switch is pressed, the auto-deceleration function is switched ON/OFF. Use the auto-deceleration monitor display to check the present condition. When the working mode switch is operated to switch the working mode, it is automatically set to ON.
•
Travel speed selector switch Each time the travel speed selector switch is pressed, the travel speed changes. Lo o Hi o Lo …… Use the travel speed monitor display to check the present condition. The relationship between the set speed and the monitor display in the table on the right.
•
MONITOR SYSTEM
Wiper switch Each time the wiper switch is pressed, the wiper setting changes OFF o INT o ON o OFF o …… Use the wiper monitor display to check the present condition. The relationship between the wiper setting and the monitor display is as shown in the table on the right.
•
Window washer switch While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts.
•
Control switch This is used for control when using the maintenance function or select function. (For details, see each function.)
•
Display brightness, contrast adjustment switch Use this switch when adjusting the display brightness and contrast. (For details, see each function.)
PC750, 800-7
Swing priority mode
Display
Setting
Crawler symbol + Lo
Low speed (default)
Crawler symbol + Hi
High speed
Display
Setting
Wiper actuation status
None
OFF
Stowing stopped or now stowing
Wiper symbol + INT
INT
Intermittent actuation
Wiper symbol + ON
ON
Continuous actuation
10-167
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
MAINTENANCE FUNCTION When the maintenance time for replacement, inspection, or filling has approached for the 10 maintenance items, press maintenance switch (1) and the caution display (yellow or red) appears on the monitor display for 30 seconds after the key is turned ON to remind the operator to carry out lubrication maintenance.
a Maintenance items No.
Item
Replacement interval (hours)
01
Engine oil
500
02
Engine oil filter
500
03
Fuel filter
500
04
Hydraulic filter
1,000
05
Hydraulic tank breather
1,000
06
Corrosion resistor
1,000
07
Damper case oil
1,000
08
Final case oil
2,000
09
Machinery case oil
1,000
10
Hydraulic oil
5,000
11
Pilot filter
500
12
Drain filter
500
a The above replacement intervals are set for each item, and the time remaining to maintenance is reduced as the machine is operated. The content of the caution display differs according to the ramaining time. The relationship is as shown in the table below. Display
Condition
None
Remaining time for maintenance for all items is more than 30 hours
Notice display (black symbol displayed on yellow background)
There is one or more items with less than 30 hours remaining time for maintenance
Warning display (wiper symbol displayed on red background)
There is one or more items with less than 0 hours remaining time for maintenance
10-168
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
METHOD OF CHECKING STATUS MAINTENANCE ITEMS a Operate as follows when on the operator screen. 1. Press maintenance switch (1) and switch to the maintenance list display screen. a The maintencance items are displayed as symbols on the screen. 2. Press control switch (2), or use the 10-key pad to input the number (01 – 10, 30, 31) of the maintenance item to select the item. a The cursor moves and the item is highlighted. a The display method is the same as described on the previous page (relationship between remaining time and caution display). If the remaining time is less than 30 hours, the item is displayed in yellow, and if it is less than 0 hours, it is displayed in red.
MAINTENANCE OPERATION 1. After completing the selection, press input confirmation switch (3). The screen will change to the maintenance reset screen. 2. Use the maintenance reset screen to check the content, and if there is any problem, press input confirmation switch (3) to move to the check screen. If the wrong item is selected, press return switch (4) to return to the maintenance list screen. 3. Check the content on the check screen, and if there is no problem, press input confirmation switch (3) to reset the maintenance time. After the reset is completed, the screen returns to the maintenance list display screen. To check the remaining time, or if the wrong item is selected, press return switch (4) to return to the maintenance list screen. a The check screen shows the symbol for the maintenance item and the set time in large letters. a The background color of the symbol for the item where the maintenance item was reset is the same as the background of the screen, so it is possible to check that it has been reset.
PC750, 800-7
10-169
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
BRIGHTNESS, CONTRAST ADJUSTMENT FUNCTION This function is used to adjust the brightness and contrast of the display. Adjustment method a Operate as follows when on the operator screen. 1. Press display brightness/contrast adjustment switch (1) and switch to the adjustment screen. a Relationship between menu symbol and content. No.
Symbol
Content
00
Return mark
Return
01
Contrast
02
Brightness
2. Press control switch (2), or use the 10-key pad to input the number (00 – 02) to select either contrast or brightness. After completing the selection, press input confirmation switch (3) and return to the adjustment screen. Then press return switch (4) or use the 10-key pad to set to [00] and press input confirmation switch (3) to return to the normal screen. 3. Press control switch (2) and adjust the brightness and contrast as desired. Control switch
Actuation Flow level bar graph extends to the right
Flow level bar graph retracts to the left
10-170 (3)
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
SERVICE METER CHECK FUNCTION •
•
When the starting switch is at the OFF position, keep return switch (1) and control switch (2) of the monitor pressed at the same time, and the service meter is shown on the display. This display is shown only while the two switches are being pressed. When the switches are released, the display goes out. Note that it takes 3 – 5 seconds after the switches are pressed for the service meter display to appear.
DISPLAY LCD CHECK FUNCTION •
On the password input screen or on the normal screen, if monitor return switch (1) and working mode (A) switch are kept pressed at the same time, all the LCD display will light up and the whole screen will become white, so the display can be checked. If any part of the display is black, the LCD is broken.
USER CODE DISPLAY FUNCTION •
•
•
If there is any problem in operating the machine, the user code is displayed on the monitor to advise the operator of the steps to take. This code display appears on the operator screen. On the operator screen, the user code is displayed on the portion for the hydraulic oil temperature gauge.
If more than one user code is generated at the same time, the user codes are displayed in turn for 2 seconds each to display all the user codes.
PC750, 800-7
10-171
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
•
While the user code is being displayed, if the input cnfirmation switch is pressed, the service code and failure code can be displayed.
•
If there is more than one service code or failure code, the display switchs every 2 seconds and displays all the service codes/failure codes that caused the user code to be displayed. Even if service codes/failure codes have occurred, if they did not cause the user code to be displayed, this function does not display them.
•
If the telephone number has been set using the telephone number input on the service menu, it is possible to switch on the service code/failure code and display the telephone symbol and telephone number. For details of inputting and setting the telephone number, see SPECIAL FUNCTIONS OF MONITOR PANEL in the TESTING AND ADJUSTING section.
10-172 (3)
MONITOR SYSTEM
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSORS
SENSORS •
The signals from the sensors are input directly to the engine controller and the pump controller monitor. Name of sensor
The contact type sensors are always connected at one end to the chassis GND.
Type of sensor
When normal
When abnormal
Input controller
Coolant level
Contact type
ON (closed)
OFF (open)
Monitor
Engine oil level
Contact type
ON (closed)
OFF (open)
Monitor
Engine oil pressure
Contact type
ON (closed)
OFF (open)
Engine controller
Coolant temperature
Resistance type
—
—
Engine controller
Fuel level
Resistance type
—
—
Monitor
Air cleaner clogging
Contact type
OFF (open)
ON (closed)
Monitor
Hydraulic oil temperature
Contact type
—
—
Monitor
Analog
—
—
Pump controller
Main pump oil pressure
Coolant level sensor
1. 2. 3. 4.
PC750, 800-7
Sub-tank Float Sensor Connector
10-173
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSORS
Engine oil level sensor
1. 2. 3. 4.
Connector Bracket Float Switch
1. 2. 3. 4. 5. 6.
Plug Contact ring Contact Diaphragm Spring Terminal
Engine oil pressure sensor
Air cleaner clogging sensor
10-174
PC750, 800-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSORS
Fuel level sensor 1. 2. 3. 4.
Float Connector Cover Variable resistor
Coolant temperature sensor Hydraulic oil temperature sensor
1. Thermistor 2. Body 3. Tube
PC750, 800-7
4. Tube 5. Wire 6. Connector
10-175
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSORS
Main pump oil pressure sensor (0 – 49.0 MPa {0 – 500 kg/cm2})
1. Sensor 2. Connector
10-176
PC750, 800-7
20 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-2 STANDARD VALUE TABLE FOR CHASSIS .................................................................................................. 20-3 TESTING AND ADJUSTING ...................................................................................................................... 20-101 TROUBLESHOOTING ................................................................................................................................ 20-201
PC750, 800-7
20-1 (1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE
Item
Machine model
PC750, SE, LC-7 PC800, SE-7
Engine
SAA6D140E-3
Measurement condition
Unit
Standard value
Permissible value
1,980 ± 50
1,980 ± 50
825 ± 25
825 ± 25
1,800
1,800
kPa {mmHg}
Min 147 {Min. 1,100}
117 {880}
°C
Max. 700
Max. 750
Max. 4.0
7.0
Max. 1.0
2.0
0.35
—
0.57
—
High idling Engine speed
Low idling
rpm
Rated speed Intake air pressure
At rated output
Exhaust gas pressure
All speed range (intake air temp: 20°C) At sudden acceleration
Bosch index
Exhaust gas color At high idling Valve clearance (normal temperature)
Intake valve mm Exhaust valve
Compression pressure
Oil temperature: 40 – 60°C (Engine speed: 160 – 200 rpm)
MPa {kg/cm2}
Min. 4.1 {Min. 42}
2.8 {29}
Blow-by pressure
(Coolant temperature: within operating range) At rated output
kPa {mmH2O}
Max. 1.96 {Max. 200}
3.9 {400}
0.34 – 0.54 {3.5 – 5.5}
0.21 {2.1}
0.29 – 0.49 {3.0 – 5.5}
0.18 {1.8}
(Coolant temperature: within operating range) At high idling Oil pressure
At high idling
(SAE30) (SAE10W)
MPa {kg/cm2}
At low idling
(SAE30)
Min. 0.12 {Min. 1.2}
0.08 {0.8}
At low idling
(SAE10W)
Min. 0.1 {Min. 1.0}
0.07 {0.7}
Oil temperature
All speed range (inside oil pan)
°C
90 – 110
120
Alternator belt tension
Deflection when pressed with finger force of approx. 58.8 N {6 kg}
mm
10 – 15
10 – 15
Air conditioner compressor belt tension
Deflection when pressed with finger force of approx. 58.8 N {6 kg}
mm
10 – 15
10 – 15
20-2 (1)
PC750, 800-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS PC750, SE, LC-7 PC800, SE-7
Applicable model
Engine speed
Category
Item
Measurement conditions
Unit
Standard value for new machine
Service limit value
Min. 1,700
Min. 1,700
Min. 1,700
Min. 1,700
All pumps at relief
• Engine water temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idling • Working mode: A • Boom up relief
Heavy lift ON + All pumps at relief
• Engine water temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idling • Working mode: A & heavy lift • Boom up relief
High idling-cut ON
• Engine at high idling • Auto-deceleration switch OFF • All control levers at neutral
1,880 ± 100
1,880 ± 100
Auto-deceleration actuated
• Engine at high idling • Auto-deceleration switch ON • All control levers at neutral
1,400 ± 100
1,400 ± 100
16 ± 0.5
16 ± 0.5
85 ± 10
85 ± 10
N o In, Out
85 ± 10
85 ± 10
N o Curl, Dump
85 ± 10
85 ± 10
N o R.H., L.H.
85 ± 10
85 ± 10
N o F, R (L.H., R.H.)
115 ± 12
115 ± 12
Work equipment, swing, travel
Max. 10
Max. 15
rpm
Boom Lo control valve
Spool stroke
Boom Hi control valve Arm Lo control valve Arm Hi control valve Bucket Lo control valve
• Stroke of each side
Bucket Hi control valve Swing control valve Travel control valve N o Raise, Lower
Travel of control levers
Boom control lever Arm control lever Bucket control lever Swing control lever Travel control lever Play of control levers
PC750, 800-7
• Center of lever knob • Read max. value to end of travel (Exclude play at neutral.) • Engine stopped
mm
20-3 (1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC750, SE, LC-7 PC800, SE-7
Applicable model Category
Item
Standard value for new machine
Service limit value
15.7 ± 4.9 {1.6 ± 0.5}
15.7 ± 4.9 {1.6 ± 0.5}
15.7 ± 4.9 {1.6 ± 0.5}
15.7 ± 4.9 {1.6 ± 0.5}
12.7 ± 3.9 {1.3 ± 0.4}
12.7 ± 3.9 {1.3 ± 0.4}
12.7 ± 3.9 {1.3 ± 0.4}
12.7 ± 3.9 {1.3 ± 0.4}
Lever
24.5 ± 5.9 {2.5 ± 0.6}
Max. 39.2 {Max. 4.0}
Pedal
74.5 ± 18.6 {7.6 ± 1.9}
Max. 107.6 {Max. 11}
31.4 ± 1.0
31.4 +1.0
{320 ± 10}
{320 –20 } 33.8 +1.0
Measurement conditions
Unit
Arm control lever Bucket control lever
• Engine at high idling • Hydraulic oil temperature: Within operating range • Center of lever knob • Measure max. value to end of travel
N {kg}
Swing control lever
Travel control lever, pedal
RAISE
Operating effort of control levers
Boom control lever
33.8 ± 1.0
At heavy lift
• Hydraulic oil Normal temperature: Within operating range At machine • Engine at high push-up idling • Working mode: A • Pump outlet pressure when meaCurl sured circuit is relieved • Relieve either Dump travel circuit.
{345 ± 10}
LOWER
Boom relief pressure
Normal
Hydraulic pressure
Arm relief pressure
Bucket relief pressure
(1)
–2.0 +10
18.6 ± 1.9
{345 –20 } 18.6 ± 1.9
{190 ± 20}
{190 ± 20}
31.4 ± 1.0
31.4 +1.0
{350 0 }
–2.0 +10 {320 –20 } 31.4 +1.0 –2.0 +10 {320 –20 } 31.4 +1.0 –2.0 +10 {320 –20 } 32.4 +1.0 –2.0 +10 {330 –20 } 28.4 +2.5 –0.5 {290 +25 } –25 34.3 +1.0 –2.0 +10 {350 –20 } 3.33 +0.49 –0 +5 {350 0 }
All control levers at neutral
2.21 ± 0.2 {22.5 ± 2}
Min. 1.76 {Min. 18}
Boom RAISE relief (Normal)
1.23 ± 0.2 {12.5 ± 2}
1.18 ± 0.2 {12 ± 2}
Heavy lift ON + Boom RAISE relief
1.19 ± 0.2 {12.1 ± 2}
1.14 ± 0.2 {11.6 ± 2}
{320 ± 10} 31.4 ± 1.0 {320 ± 10} 31.4 ± 1.0 {320 ± 10} 32.4 ± 1.0 MPa {kg/cm2}
{330 ± 10} 28.4 +2.5 –0.5
Swing relief pressure
{290 +25 } –25
34.3 ± 1.0
Travel relief pressure
20-4
–2.0 +10
{350 ± 10}
Control pressure
• Hydraulic oil temperature: Within operating range • Engine at high idling
TVC valve output pressure
• Hydraulic oil temperature: Within operating range • Engine at high idling • Working mode: A
3.33 +0.49 –0 +5
PC750, 800-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC750, SE, LC-7 PC800, SE-7
Applicable model Category
Item
Swing
Hydraulic pressure
CO-NC valve output pressure
Standard value for new machine
Service limit value
Max. 0.4 {Max. 4}
Max. 0.55 {Max. 5.5}
Boom RAISE relief (Normal)
1.23 ± 0.2 {12.5 ± 2}
1.18 ± 0.2 {12 ± 2}
Track running idle (Lever at stroke end)
Min. 1.67 {Min. 17}
Min. 1.67 {Min. 17}
Heavy lift ON + Boom RAISE relief
1.19 ± 0.2 {12.1 ± 2}
1.14 ± 0.2 {11.6 ± 2}
Min. 1.14 {Min. 11.6}
Min. 1.14 {Min. 11.6}
Max. 0.15 {Max. 1.5}
Max. 0.15 {Max. 1.5}
Max. 2.0 {Max. 20}
Max. 2.9 {Max. 30}
Max. 60 (Max. 1,035)
Max. 80 (Max. 1,380)
Measurement conditions • Hydraulic oil temperature: Within operating range • Engine at high idling • Working mode: A • When track runs idle, measure oil pressure on idle side.
All control levers at neutral
Jet sensor output negative pressure
• Hydraulic oil temperature: Within operating range • Engine at high idling • Working mode: A
PPC valve output pressure
• Hydraulic oil temperature: Within operating range • Engine at high idling • Control lever at stroke end
Oil pressure drop
• Hydraulic oil temperature: Within operating range • Difference between relief pressure at high idling and that at low idling
All control levers at neutral
MPa {kg/cm2}
Track running idle (Lever at stroke end)
Overrun when stopping • Hydraulic oil temperature: Within operating range swing • Bucket: No load • Engine at high idling • Working mode: A • Stop after swinging one turn and measure distance that swing circle moves
PC750, 800-7
Unit
deg. (mm)
20-5 (1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC750, SE, LC-7 PC800, SE-7
Applicable model Category
Item
Measurement conditions
Standard value for new machine
Service limit value
4.4 ± 0.5
Max. 5.3
6.8 ± 0.7
Max. 8.2
sec.
41 – 47
Max. 50
mm
0
0
l/min
Max. 5
Max. 10
Unit
90°
Time taken to start swing
Swing
Time taken to swing
• Hydraulic oil temperature: Within operating range • Bucket: No load • Engine at high idling • Working mode: A • Time taken to swing 90° and 180° from starting position
sec.
180°
• Hydraulic oil temperature: Within operating range • Bucket: No load • Engine at high idling • Working mode: A • Swing one turn, then measure time taken to swing next 5 turns
• Hydraulic oil temperature: Within operating range Hydraulic drift of swing • Engine stopped • Set machine on 15° slope, and set upper structure at 90° to the side. • Make match marks on inner race and outer race of circle. • Measure distance that match marks move apart after 5 minutes.
Leakage from swing motor
20-6 (1)
• Hydraulic oil temperature: Within operating range • Engine at high idling • Swing lock switch: ON • Leakage in 1 minute during swing relief
PC750, 800-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC750, SE, LC-7 PC800, SE-7
Applicable model Category
Item
Standard value for new machine
Service limit value
74 – 90 (PC750LC-7: 80 – 98)
74 –90 (PC750LC-7: 80 – 98)
Hi
48 – 59 (PC750LC-7: 52 – 64)
48 – 59 (PC750LC-7: 52 – 64)
Lo
22 – 29
22 – 29
15 – 19
15 – 19
Max. 200
Max. 220
Measurement conditions
Unit
Lo
Travel speed (Idle travel)
Travel
Travel speed (Actual travel)
Travel deviation
PC750, 800-7
• Hydraulic oil temperature: Within operating range • Engine at high idling • Working mode: A • Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns with no load.
• Hydraulic oil temperature: Within operating range • Engine at high idling • Working mode: A • On flat place • Run up for at least 10 m, and measure time taken to travel next 20 m on flat ground.
sec.
sec.
Hi
• Hydraulic oil temperature: Within operating range • Engine at high idling • Working mode: A • Travel speed: Lo • On hard and flat place • Measure travel deviation (x) in travel of 20 m after running up 10 m.
mm
20-7 (1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC750, SE, LC-7 PC800, SE-7
Applicable model Category
Item
Travel
Hydraulic drift of travel
Leakage of travel motor
Measurement conditions
• Hydraulic oil temperature: Within operating range • Engine stopped • Stop machine on 12° slope with sprocket at uphill end of machine. • Measure the distance the machine moves in 5 minutes. • Hydraulic oil temperature: Within operating range • Engine at high idling • Travel: Lock sprocket. • Measure leakage in 1 minute during travel relief.
Unit
Standard value for new machine
Service limit value
mm
0
0
l/min
Max. 20
Max. 40
Max. 1,400 (Max. 900)
Max. 1,800 (Max. 1,000)
60 (35)
Max. 90 (Max. 50)
165 (70)
Max. 250 (Max. 105)
50 (15)
Max. 75 (Max. 25)
Hydraulic drift of work equipment
Work equipment
Total work equipment (hydraulic drift at tip of bucket teeth)
Boom cylinder (amout of retraction of cylinder)
Arm cylinder (amount of extension of cylinder)
Bucket cylinder (amount of retraction of cylinder)
20-8 (1)
• Hydraulic oil temperature: Within operating range • On level and flat place • Work equipment: In above measuring posture with rated load Standard (LC): 49 kN {5,000 kg} SE: 64 kN {6,500 kg} • Engine: Stopped • Work equipment control lever: Neutral • Start measuring just after setting machine and measure every 5 minutes for 15 minutes. • Figures in ( ) are for empty work equipment.
mm
PC750, 800-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC750, SE, LC-7 PC800, SE-7
Applicable model
PC750, 800-7
RAISE • Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Measure time taken to move bucket between DUMP stroke end and CURL stroke end (including operating time of cylinder cushion).
Service limit value
PC750 (LC): 5.3 ± 0.5 PC750SE: 5.6 ± 0.6 PC800: 5.3 ± 0.5 PC800SE: 5.6 ± 0.6
PC750 (LC): PC750SE: PC800: PC800SE:
Max. 6.7 Max. 7.2 Max. 6.7 Max. 7.2
LOWER
Bucket speed
• Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Measure time taken to move arm between OUT stroke end and IN stroke end (including operating time of cylinder cushion).
Standard value for new machine
PC750 (LC): 4.3 ± 0.4 PC750SE: 4.4 ± 0.4 PC800: 4.2 ± 0.4 PC800SE: 4.4 ± 0.4
PC750 (LC): PC750SE: PC800: PC800SE:
Max. 5.1 Max. 5.2 Max. 5.0 Max. 5.2
IN Arm speed
• Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Measure time taken to move bucket between RAISE stroke end and ground touch point of bucket (including operating time of cylinder cushion).
Unit
PC750 (LC): 4.7 ± 0.5 PC750SE: 5.4 ± 0.5 PC800: 5.4 ± 0.5 PC800SE: 5.4 ± 0.5
PC750 (LC): PC750SE: PC800: PC800SE:
Max. 5.9 Max. 6.6 Max. 6.6 Max. 6.6
OUT
Work equipment speed
Work equipment
Boom speed
Measurement conditions
PC750 (LC): 3.6 ± 0.3 PC750SE: 4.1 ± 0.4 PC800: 4.1 ± 0.4 PC800SE: 4.1 ± 0.4
PC750 (LC): PC750SE: PC800: PC800SE:
Max. 4.6 Max. 5.1 Max. 5.1 Max. 5.1
CURL
Item
PC750 (LC): 3.3 ± 0.3 PC750SE: 4.6 ± 0.5 PC800: 3.6 ± 0.4 PC800SE: 4.6 ± 0.5
PC750 (LC): PC750SE: PC800: PC800SE:
Max. 3.9 Max. 5.6 Max. 4.4 Max. 5.6
DUMP
Category
PC750 (LC): 3.5 ± 0.3 PC750SE: 4.2 ± 0.4 PC800: 3.7 ± 0.3 PC800SE: 4.2 ± 0.4
PC750 (LC): PC750SE: PC800: PC800SE:
Max. 4.1 Max. 5.0 Max. 4.3 Max. 5.0
sec.
20-9 (1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC750, SE, LC-7 PC800, SE-7
Applicable model Category
Item
Time lag
Work equipment
Boom time lag
Arm time lag
Pump performance
Oil leakage
Bucket time lag
(1)
Unit
• Hydraulic oil temperature: Within operating range • Engine: Low idling • Working mode: A • Lower boom from RAISE stroke end and measure time taken to lift up front side of machine after bucket touches ground.
• Hydraulic oil temperature: Within operating range • Engine: Low idling • Working mode: A • Move in arm from OUT stroke end and measure time taken to start moving arm again after it is stopped.
sec.
• Hydraulic oil temperature: Within operating range • Engine: Low idling • Working mode: A • Curl bucket from DUMP stroke end and measure time taken to start moving bucket again after it is stopped.
• Hydraulic oil temperature: Within operating range • Engine: High idling • Relieve cylinder to be measured or travel circuit and meaCenter swivel joint sure leakage in 1 minute. Cylinder
Hydraulic pump discharge amount
20-10
Measurement conditions
• See following page.
Standard value for new machine
Service limit value
Max. 6
Max. 6
Max. 5
Max. 5
Max. 4
Max. 4
Max. 5
Max. 20
Max. 10
Max. 100
cc/min
l/min
See following page.
PC750, 800-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Performance of hydraulic pump
CateDischarge amount of one hydraulic pump gory
• TVC current : 400 mA • Pump speed: At 2,400 rpm (Engine rated speed at 1,800 rpm)
Check point
Test pump discharge pressure (MPa {kg/cm2}
Discharge pressure of other pump (MPa {kg/cm2})
Average pressure (MPa {kg/cm2})
Standard value for discharge amount Q (l/min)
Judgement standard lower limit Q (l/min)
As desired
P1
P2
P1 + P2 2
See graph
See graph
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring. The error is large near the point where the graph curves, so avoid measuring at this point. a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
PC750, 800-7
20-11 (1)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING........................................................... 20-102 MEASURING ENGINE SPEED .................................................................................................................. 20-104 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) ................................................................ 20-105 MEASUREMENT OF EXHAUST GAS TEMPERATURE............................................................................ 20-106 MEASUREMENT OF EXHAUST GAS COLOR.......................................................................................... 20-107 ADJUSTING VALVE CLEARANCE............................................................................................................. 20-108 MEASURING COMPRESSION PRESSURE.............................................................................................. 20-109 MEASURING BLOW-BY PRESSURE ........................................................................................................ 20- 111 MEASURING ENGINE OIL PRESSURE .................................................................................................... 20- 112 HANDLING OF FUEL SYSTEM EQUIPMENT ........................................................................................... 20-113 REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT ................................................. 20- 113 MEASUREMENT OF FUEL PRESSURE ................................................................................................... 20- 114 AIR BLEEDING FROM FUEL CIRCUIT ..................................................................................................... 20- 115 INSPECTION OF LEAKAGE FROM FUEL SYSTEM................................................................................. 20- 117 TESTING AND ADJUSTING FAN BELT TENSION.................................................................................... 20- 119 TESTING AND ADJUSTING ALTERNATOR BELT TENSION ................................................................... 20-120 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT................................................. 20-121 INSPECTION OF SWING CIRCLE BEARING CLEARANCE..................................................................... 20-122 TESTING AND ADJUSTING TRACK SHOE TENSION ............................................................................. 20-123 TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES.......................................................................................... 20-124 TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE......................................................... 20-129 TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE ..................................................... 20-130 INSPECTION OF SERVO PISTON STROKE ............................................................................................ 20-136 MEASUREMENT OF PPC VALVE OUTPUT PRESSURE ......................................................................... 20-137 MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTOR VALVE ...................................................................................... 20-140 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE........................................................................... 20-145 TESTING AND ADJUSTING TRAVEL DEVIATION.................................................................................... 20-146 INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT................................... 20-148 MEASURING OIL LEAKAGE...................................................................................................................... 20-149 RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT..................................................... 20-153 BLEEDING AIR FROM EACH PART .......................................................................................................... 20-154 INSPECTION PROCEDURES FOR DIODE............................................................................................... 20-157 SPECIAL FUNCTION OF MONITOR PANEL............................................................................................. 20-158 HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT .............................................................. 20-185 PREPARATION WORK............................................................................................................................... 20-186 Pm-CLINIC SERVICE ................................................................................................................................. 20-189 UNDERCARRIAGE INSPECTION ............................................................................................................. 20-196
PC750, 800-7
20-101 (1)
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Measuring intake air pressure (boost pressure)
A
799-201-2202 Boost gauge kit
1
–101 to 200 kPa {–760 to 1,500 Hg}
Measuring exhaust temperature
B
799-101-1502 Digital thermometer
1
–99.9 to 1,299 ºC
1 799-201-9000 Handy smoke checker
1
2
Measuring exhaust gas color Adjusting valve clearance
C D
Part No.
Part name
Measuring blow-by pressure
Measuring engine oil pressure
Measuring fuel pressure
E
2 F
Purchased
Smoke meter
1
Purchased
Feeler gauge
1
(Intake: 0.35 mm, Exhaust: 0.57 mm)
1
0 to 6.9 MPa {0 to 70 kg/cm2}
795-471-1310 Adapter
1
For 140E-3 engine
6217-71-6110
1
For 140E-3 engine
1
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester
1
Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester
1
Pressure gauge: 0.98 MPa {10 kg/cm2}
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester
1
Pressure gauge: 58.8 MPa {600 kg/cm2}
1
Pressure gauge: 0.98 MPa {10 kg/cm2}
1
With magnet
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester
1
Pressure gauge: 58.8 MPa {600 kg/cm2}
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester
1
Pressure gauge: 58.8 MPa {600 kg/cm2}
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester
1
Pressure gauge: 58.8 MPa {600 kg/cm2}
1
H
Gasket
799-201-1504 Blow-by checker
1
G
2 799-401-2320 Hydraulic tester Measuring clearance of swing circle bearing Testing and adjusting in work equipment, swing, and travel circuit oil pressures
J
Purchased
L
1 Testing and adjusting control oil pressure of piston pump
Differential pressure M 2 799-401-2701 gauge 3
Testing servo piston stroke
N
(1)
1
799-101-5220 Nipple
2
07002-11023
2
O-ring
4 799-401-3200 Adapter
2
708-25-14140 Cap
1
07000-B2065
O-ring
1
566-98-41120
Disc gauge
1
1 2
20-102
Dial gauge
K
Testing and adjusting control circuit oil pressure
Remarks
Pollution level: 0 to 70% (With standard color) (Pollution level × 1/10 C Bosch index)
1 795-502-1590 Compression gauge Measuring compression pressure
Q’ty
Test, measuremnt item
symbol
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Size: 10 × 1.25 mm
Size: 03 For HPV95 + 95 pump
PC750, 800-7
Measuring PPC valve output pressure
Q’ty
Test, measuremnt item
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
symbol
TESTING AND ADJUSTING
Remarks
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester
1
Pressure gauge: 58.8 MPa {600 kg/cm2}
1
Size: 03
799-101-5002 Hydraulic tester
1
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester
1
Pressure gauge: 58.8 MPa {600 kg/cm2}
Q 2 799-401-3200 Adapter
1
Size: 03
3 799-401-3300 Adapter
1
Size: 04
799-101-5220 Nipple
2
Size: 10 × 1.25 mm
07002-11023
O-ring
2
Measuring cylinder
1
Wear gauge
1
P
1
Part No.
Part name
2 799-401-3200 Adapter 1 Measuring outlet pressure of solenoid valve, swing PPC shuttle valve, and swing priority selector valve
4 Measuring oil leakage
R
Purchased
Measuring wear of sprocket
—
796-627-1110
Measuring water temperature and oil temperature
—
799-101-1502 Digital thermometer
1
–99.9 to 1,299 ºC
Measuring operating effort and pressing force
—
79A-264-0021 Push-pull scale
1
0 to 294 N {0 to 30 kg}
79A-264-0091 Push-pull scale
1
0 to 490 N {0 to 50 kg}
Measuring stroke and hydraulic drift
—
Purchased
Scale
1
Measuring work equipment speed
—
Purchased
Stopwatch
1
Measuring voltage and resistance
—
Purchased
Multimeter
1
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Connector arrangement drawing and electric circuit diagram of each system.
PC750, 800-7
20-103 (1)
TESTING AND ADJUSTING
MEASURING ENGINE SPEED
MEASURING ENGINE SPEED a Measure the engine speed under the following condition. • Engine water temperature: Within operating range • Hydraulic oil temperature: Within operating range 1. Preparation work Turn the starting switch ON and set the monitor panel to "Monitoring". a For the operating method, see "Special functions of monitor panel". a Monitoring code: 01002 Engine speed 01006 Engine speed a Code 01002 is information of the engine controller and code 01006 is information of the pump controller. The engine speed can be measured with either of those codes. a The engine speed is displayed in rpm.
4. Measuring all-pump relief speed 1) Start the engine and set the fuel control dial in the high idling position (MAX). 2) Set the working mode switch in the A-mode position. 3) Turn the heavy lift switch OFF. 4) Relieve the boom circuit by raising the boom and measure the engine speed. 5. Measuring heavy-lift ON + all-pump relief speed 1) Start the engine and set the fuel control dial in the high idling position (MAX). 2) Set the working mode switch in the A-mode position. 3) Turn the heavy lift switch ON. 4) Relieve the boom circuit by raising the boom and measure the engine speed. 6. Measuring high idling-cut ON speed 1) Start the engine and set the fuel control dial in the high idling position (MAX). 2) Turn the auto-decelerator switch OFF. 3) Set the work equipment control, swing control, and travel levers in neutral and measure the engine speed when the high idlingcut function is turned ON. a The engine speed lowers to a certain level approx. 4 seconds after all the control levers are set in neutral. This level is the high idling-cut ON speed.
2. Measuring low idling speed 1) Start the engine and set the fuel control dial in the low idling position (MIN). 2) Set the work equipment control, swing control, and travel levers in neutral and measure the engine speed. 3. Measuring high idling speed 1) Start the engine and set the fuel control dial in the high idling position (MAX). 2) Set the working mode switch to the A-mode position. 3) Turn the auto-decelerator switch OFF. 4) Turn the swing lock switch ON, release the safety lock lever, and measure the engine speed while operating the swing control lever finely. a Operate the swing control lever to a degree that the PPC oil pressure switch is turned ON. Do not relieve the swing circle.
20-104 (1)
7. Measuring auto-deceleration ON speed 1) Start the engine and set the fuel control dial in the high idling position (MAX). 2) Turn the auto-deceleration switch ON. 3) Set the work equipment control, swing control, and travel control levers in neutral. When the auto-decelerator operates, measure the engine speed. a The engine speed lowers to a certain level about 6 seconds after all the levers are set in neutral. This level is the autodeceleration speed.
PC750, 800-7
TESTING AND ADJUSTING
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) a Measuring instruments for intake air pressure (boost pressure) Symbol
Part No.
A
799-201-2202
Part Name Boost gauge kit
a When installing and removing the measuring instruments, take care not to touch a hot part of the engine. a Measure the intake air pressure (boost pressure) under the following condition. • Engine water temperature: Within operating range • Hydraulic oil temperature: Within operating range 1. Open the engine compartment cover on the counterweight side.
4. Run the engine at a medium or higher speed and drain the oil from the hose. a Insert the connecting parts of the gauge and hose about a half and open the self-seal on the hose side repeatedly, and the oil will be drained. a If Pm kit is available, the air bleed coupling (790-261-1130) inside the kit can also be used. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil. 5. Set the working mode switch to A mode and turn the heavy lift switch ON. 6. Run the engine at high idling and measure the air supply pressure (boost pressure) when the boom RAISE circuit is relieved.
2. Remove intake air pressure pickup plug (1).
7. After completing the measurement, remove the measuring equipment and set to the original condition. 3. Install nipple [1] of boost gauge kit A and connect gauge [2].
PC750, 800-7
20-105 (1)
TESTING AND ADJUSTING
MEASUREMENT OF EXHAUST GAS TEMPERATURE
MEASUREMENT OF EXHAUST GAS TEMPERATURE a Measuring instrument of exhaust gas temperature Symbol
Part No.
B
799-101-1502
Part Name Digital thermometer
k Wait for the temperature of the exhaust manifold to go down before removing or installing the measuring equiment. a Measure the exhaust temperature under the following conditions. • Coolant temperature: Within operating range • Hydraulic oil temperature: Within operating range
3. Install sensor [1] of digital thermometer B and connect them to meter [2]. a Clamp the wiring harness of the digital temperature gauge so that it does not touch any high temperature part during the measurement.
1. Open the engine compartment cover on the counterweight side and remove turbocharger heat insulation cover (1). 4. Procedure for measuring maximum exhaust temperature for troubleshooting Operate the machine actually and measure the maximum exhaust temperature. a Set the digital thermometer in the PEAK mode.
2. Remove exhaust temperature pickup plug (2).
5. Procedure for measuring exhaust temperature periodically for preventive maintenance (Pm Clinic), etc. 1) Set the working mode switch in the A-mode position and turn the heavy lift switch ON. 2) Run the engine at high idling, relieve the boom circuit by raising the boom, and measure the exhaust temperature. a Measure the exhaust temperature after it is stabilized.
6. After completing the measurement, remove the measuring equipment and set to the original condition.
20-106 (1)
PC750, 800-7
TESTING AND ADJUSTING
MEASUREMENT OF EXHAUST GAS COLOR
MEASUREMENT OF EXHAUST GAS COLOR a Measuring instrument of exhaust gas color Symbol
Part Number
1
799-201-9000
2
Purchased
C
Part Name Handy smoke checker Smoke meter
k Be careful not to touch hot areas when mounting and removing the measuring instrument. a When air source or electric power supply is not a v a i l a bl e i n fi e l d , u s e C1 Ha n d y S m ok e Checker, but use C2 Smoke Meter, when recording official data. a Measure exhaust gas color under the following conditions: • Engine water temperature:Within the operating temperature range. 1. Measurement with C1, Handy Smoke Checker 1) Set a filter paper in the handy smoke checker C1. 2) Insert the exhaust gas suction port in the exhaust pipe (1). 3) Start the engine. 4) Operate the handle of the smoke checker C1, and adhere exhaust gas to the filter paper when accelerating the engine quickly or at a high idling.
5) Remove the filter paper and compare the color on the filter paper with the accessory scale. 6) After the measurement, remove the measuring instrument and return the engine to the original state. 2. Measurement with Smoke Meter C2 1) Insert the probe [1] of the smoke meter C2, in the outlet of the exhaust pipe (1) and fix it to the exhaust pipe with clip.
PC750, 800-7
2) Connect the prove hose, the receptacle of the accelerator switch and the air hose to the smoke meter C2. a The supply air pressure shall be less than 1.5 MPa {15 kg/cm2} 3) Connect the power cord to an AC100V receptacle. a Before connecting the power cord, make sure that the power switch of the smoke meter is turned off. 4) Loosen the cap nut of the suction pump and set a filter paper there. a Set the filter paper accurately so that exhaust gas does not leak out. 5) Turn on the power switch of the smoke meter C2.
6) Start the engine. 7) When accelerating the engine quickly or at a high idling, step down the accelerator pedal of the smoke meter C2, and collect exhaust gas in the filter paper. 8) Place the filter paper contaminated with exhaust gas on new filter papers (more than 10 sheets) in the filter paper holder and read the indicated value. 9) After the measurement, remove the measuring instrument and return the engine to the original state.
20-107 (1)
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE a Adjusting tools for valve clearance Symbol
Part No.
D
Purchased
Part Name Feeler gauge
1. Remove the engine hood assembly and all cylinder head covers (1). 4
Engine hood assembly: 260 kg
2. Rotate the crankshaft in the normal direction to align [1.6 TOP] line a on the damper with pointer (2), and set the No.1 cylinder compression to top dead center. a Check the pointer from the air compressor side. a Crank the engine with the hexagonal part at the water pump drive shaft on the alternator side. a At the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by hand an amount equal to the valve clearance. If the rocker arm does not move, it is not at the compression top dead center, so rotate the crankshaft one more turn.
20-108 (1)
3. Insert feeler gauge D in clearance b between rocker arm (3) and crosshead (4), and turn adjustment screw (5) to adjust the valve clearance. a With feeler gauge D inserted, turn the adjustment screw and adjust until the clearance is a sliding fit. 4. Tighen locknut (6) to hold adjustment screw (5) in position. 3 Locknut: 53.0 – 64.7 Nm {5.4 – 6.6 kgm} a After tightening the locknut, check the valve clearance again.
5. Rotate the crankshaft 120° each time in the normal direction and repeat Steps 2 - 4 to adjust the valve clearance of each cylinder according to the firing order. a Firing order: 1-5-3-6-2-4 6. After comleting the adjustment, set to the original condition. 3 Mounting bolt of cylinder head cover: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
PC750, 800-7
TESTING AND ADJUSTING
MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE a Measuring instruments for compression pressure Symbol
Part No.
1 E
2
Part Name
795-502-1590
Compression gauge
795-471-1310
Adapter
6217-71-6110
Gasket
a Pass a wire, etc. under the fuel path projected sideways and pull up the injector (Do not pry the injector top up).
a When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. a Measure the compression pressure under the following condition. • Engine oil temperature: 40 – 60°C 1. Remove the engine hood assembly and head cover (1) of the cylinder to measure the compression pressure. 4
Engine hood assembly: Approx. 260 kg
4. Install adapter E2 and connect it to compression gauge E1. a Secure the adapter with the injector holder. 3 Mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily. 5. Install rocker arm assembly (2) and adjust the valve clearance. 3 Mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm} a See ADJUSTING VALVE CLEARANCE.
2. Remove rocker arm assembly (2). a Referring to ADJUSTING VALVE CLEARANCE, set the cylinder to be measured at the compression top dead center so that you can work easily. 3. Disconnect fuel high-pressure tube (3) and remove the injector wiring harness and injector (4). a Use a high-pressure pipe ring wrench (on the market) to disconnect and connect the fuel high-pressure tube. At this time, loosen the clamps on the common rail side and at the intermediate part. a Disconnect the terminal of the injector wiring harness on the injector side and the bracket on the rocker housing side and remove the injector wiring harness (Loosen the terminal nuts alternately).
PC750, 800-7
20-109 (1)
TESTING AND ADJUSTING
6. Disconnect engine intermediate connectors E21 (5) and E22 (6).
k If these connectors are not disconnected, the engine may start while your are measuring, and that is dangerous. Accordingly, be sure to disconnect the connectors. k Cover the connector on the controller side (body side) with a vinyl sheet, etc. to prevent electric leakage and grounding fault.
MEASURING COMPRESSION PRESSURE
3) Tighten sleeve nut (14) of the fuel high-pressure tube to injector (11) lightly. a Use a high-pressure pipe ring wrench (on the market) to disconnect and connect the fuel high-pressure tube. a Tighten the sleeve nut lightly until it is stopped by the injector. 4) Tighten mounting bolt (13) securely. 3 Mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} 5) Tighten sleeve nut (14) of the fuel high-pressure tube securely. 3 Sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm} 6) Tighten the intermediate clamp of the fuel high-pressure tube. 7) Install the injector wiring harness. a Tighten the terminal nuts at the injector top alternately. 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
7. Turn the starting switch ON and prepare for measuring the engine speed with the monitor panel. a See MEASURING ENGINE SPEED. 8. Crank the engine with the starting motor and measure the compression pressure. a Read the pressure gauge pointer when it is stabilized. a When measuring the compression pressure, measure the engine speed, too, and check that it is in the measurement condition range. 9. After finishing measurement, remove the measuring instruments and return the removed parts. a Install the injector and fuel high-pressure tube according to the following procedure. 1) Assemble injector (11) and holder (12) together and set them to the mounting position of the cylinder head. a When setting the injector, pull the fuel high-pressure tube to outside of the cylinder head so that the threads of the injector will not interfere with the taper seal of the fuel high-pressure tube. 2) Tighten mounting bolt (13) temporarily. a Tighten the mounting bolt to a degree that you can move the injector.
20-110 (1)
a After installing the rocker arm assembly, adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE. 3 Rocker arm assembly mounting bolt: 93 – 103 Nm {9.5 – 10.5 kgm}
PC750, 800-7
TESTING AND ADJUSTING
MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE a Measuring instruments for blow-by pressure Symbol
Part No.
F
799-201-1504
Part Name Blow-by checker
a Measure the blow-by pressure under the following conditions. • Coolant temperature: Within operating range • Hydraulic oil temperature: Within operating range 1. Install the nozzle of blow-by checker F to blowby hose (1). 2. Connect the nozzle [1] and gauge [2] with the hose.
3. Start the engine and set the working mode switch to the A-mode position. 4. Run the engine at high idling, relieve the arm circuit by moving the arm IN, and measure the brake oil pressure.
5. After finishing measurement, remove the measuring instruments and return the removed parts.
PC750, 800-7
20-111 (1)
TESTING AND ADJUSTING
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE
a Measuring instruments for engine oil pressure Symbol
G
1 2
Part No.
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
799-401-2320
Hydraulic tester
4. Start the engine and measure the oil pressure with the engine at low idling and high idling.
a Measure the engine oil pressure under the following conditions. • Coolant temperature: Within operating range 1. Open the engine compartment cover on the control valve side. 2. Remove engine oil low-pressure switch (1) or oil high-pressure switch (2). a After removing the switch, wind the wiring harness with tape to prevent it from contacting the cylinder block.
5. After completing the measurement, remove the measuring equipment and set to the original condition. 3 Oil pressure switch: 2.9 – 5.9 Nm {0.3 – 0.6 kgm}
3. Install nipple [1] of hydraulic tester G1 and connect them to hydraulic tester G2.
20-112 (1)
PC750, 800-7
TESTING AND ADJUSTING
HANDLING OF FUEL SYSTEM EQUIPMENT REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT
HANDLING OF FUEL SYSTEM EQUIPMENT
REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT
a Precautions in Inspection and Maintenance of Fuel System Equipment The common rail type fuel injection system (CRI) is composed of more precise components than the usual fuel injection pump and nozzle and will probably get out of order when foreign matters enters the system. During inspection and maintenance of the fuel system, pay more attention to foreign matters than in case of usual fuel injection pumps and wash the system carefully with clean fuel if dusts enter the system.
a While the engine is rotating, pressures occur in the low pressure circuit and the high pressure circuit of the fuel system. Low pressure circuit : Among Feed pump – Fuel filter – Fuel supply pump High pressure circuit : Among Fuel supply pump – Common rail – Fuel injector a When 30 seconds elapse after the engine stopped, pressures in both the low pressure circuit and the high pressure circuit drop to the safe level automatically. a Since pressure remaining in the fuel system should be relieved certainly before inspection of the fuel system and mounting and removing of equipment, be sure to observe the following precautions: k Inspect the fuel system or mount or remove equipment more than 30 seconds later after the engine stopped and after pressure remaining in the fuel system is relieved. (Pressure remains in the fuel system right after the engine stopped, so do not start any work until 30 seconds elapse.)
a Precautions in Replacement of Fuel Filter Cartridge Be sure to use genuine fuel filter cartridge of Komatsu. The common rail type fuel injection system (CRI) is composed of more precise components than the usual fuel injection pump and nozzle and is equipped with special filter with highly efficient filtration performance to prevent foreign matters from entering the system. Therefore, be sure to use genuine filters only. Otherwise, the fuel system will possibly get out of order.
PC750, 800-7
20-113 (1)
TESTING AND ADJUSTING
MEASUREMENT OF FUEL PRESSURE
MEASUREMENT OF FUEL PRESSURE a Measuring Instrument of Fuel Pressure Symbol
H
1 2
Part Number
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital type hydraulic tester
799-401-2320
Hydraulic tester
4. Start the engine and measure fuel pressure at the time of high idling. a If the fuel pressure is in the following range, it is normal. Fuel pressure: 0.15 – 0.3 MPa {1.5 – 3 kg/cm2}
a Measure fuel pressure in the low pressure circuit among the feed pump – the fuel filter – the fuel supply pump. k Since very high pressure are generated in the high pressure circuit among the fuel supply pump – the common rail – the fuel injector, they cannot be measured in the circuit. 1. Open the engine compartment cover on the control valve side. 2. Remove the fuel pressure measurement plug (1).
5. After the measurement, return the circuit to the original state.
3. Attach the nipple [1] of the hydraulic tester H1, and connect the hydraulic tester H2.
20-114 (1)
PC750, 800-7
TESTING AND ADJUSTING
AIR BLEEDING FROM FUEL CIRCUIT
AIR BLEEDING FROM FUEL CIRCUIT
a When the fuel has run out, or after mounting or removing any device to or from the fuel circuit, bleed air from the circuit as follows: a Open the engine compartment cover on the control valve side. 1. Remove the fuel filter (1), fill the circuit with the fuel and mount the filter again. a Fill the circuit with clean fuel and be careful to prevent dusts from entering the circuit. a Pour the fuel in the inlet ports (1a) (at 8 places) of the filter. The portion (1b) is the outlet port (clean side) after filtration, and do not pour the filter in this port. a When clean fuel is not readily available, do not remove the fuel filter and fill the filter with the fuel by operating the priming pump.
PC750, 800-7
20-115 (1)
TESTING AND ADJUSTING
AIR BLEEDING FROM FUEL CIRCUIT
2. Remove the air bleeding plug (2a) from the fuel filter and operate the priming pump (3). a Keep operating the priming pump until the fuel comes out of the plug hole, and attach the plug to the fuel filter when checking the fuel. 3 Air bleeding plug : 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3. Remove the plug (2b) from the fuel filter and operate the priming pump (3). a Keep operating the priming pump until the fuel comes out of the plug hole, and attach the plug to the fuel filter when checking the fuel. 3 Air bleeding plug : 3.8 – 6.9 Nm {0.4 – 0.7 kgm} 4. Loosen the air bleeder (4) on the fuel supply pump and operate the priming pump (3) 90 to 100 times. a Keep operating the priming pump until the fuel comes out of the bleeder, and tighten the bleeder when you could check the fuel. Then, operate the priming pump several times until it become tight. 3 Air bleeder : 4.9 – 6.9 Nm {0.5 – 0.7 kgm} 5. Crank the engine with the starting motor and start the engine. a When the engine is cranked, air is bled automatically from the high pressure circuit. a When the engine does not start, air would not have been bled sufficiently from the low pressure circuit. Execute the procedures again from Step 2.
20-116 (1)
PC750, 800-7
TESTING AND ADJUSTING
INSPECTION OF LEAKAGE FROM FUEL SYSTEM
INSPECTION OF LEAKAGE FROM FUEL SYSTEM k Since very high pressures are generated in the high pressure fuel circuit, there is a danger of getting fire if fuel leaks while the engine is running. After inspecting the fuel circuit or mounting or removing equipment to or from the fuel circuit, execute the following procedures to check if fuel is leaking. a Clean and degrease the engine body and the area around before inspection so that fuel leakage can be checked easily. 1. Spray color checker (developer) to the connections of the fuel supply pump, the common rail, the fuel injector and the high pressure pipe. 2. Start the engine, keep the speed below 1,000 rpm and stop the engine when the rotation became stable. 3. Check if fuel is leaking from the fuel pipe and equipment. a Check if fuel is leaking from the high pressure circuit, mainly from the area where color checker was sprayed. a When finding fuel leakage, repair the relevant portions. Then, repeat the procedures from Step 2 to check that there is no leakage from the relevant portions.
7. Check if fuel is leaking from the fuel pipe and equipment. a Check if fuel is leaking from the high pressure circuit, mainly from the area where color checker was sprayed. a When finding fuel leakage, repair the relevant portions. Then, repeat the procedures from Step 2 to check that there is no leakage from the relevant portions. 8. Start the engine and keep low idling. Apply any load to the engine. a Relieve the arm IN. 9. Check if fuel is leaking from the fuel pipe and equipment. a Check if fuel is leaking from the high pressure circuit, mainly from the area where color checker was sprayed. a When finding fuel leakage, repair the relevant portions. Then, repeat the procedures from Step 2 to check that there is no leakage from the relevant portions. a When no leakage is found, end the inspection.
4. Start the engine and keep low idling. 5. Check if fuel is leaking from the fuel pipe and equipment. a Check if fuel is leaking from the high pressure circuit, mainly from the area where color checker was sprayed. a When finding fuel leakage, repair the relevant portions. Then, repeat the procedures from Step 2 to check that there is no leakage from the relevant portions. 6. Start the engine and keep high idling.
PC750, 800-7
20-117 (1)
TESTING AND ADJUSTING
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR a Adjust the engine speed sensor for the pump controller as follows. a The engine G rotation sensor and engine Ne rotation sensor for the engine controller cannot be adjusted. a Open the engine compartment cover on the control valve side. Before adjusting speed sensor (1), remove it and check that its tip is free from steel chips and flaws, and then install it again.
1. Screw in sensor (1) until the tip contacts the tip of the tooth of flywheel ring gear (2). 2 Thread: Hydraulic sealant 2. Turn sensor (1) back 1/2 – 2/3 turns. a This makes clearance a of 0.75 – 1.00 mm between the tip of the sensor and the tip of the gear tooth. 3. Hold sensor (1) in position with nut (3). 3 Nut: 69 – 74 Nm {7.0 – 7.5 kgm}
4. After finishing adjustment, check that the monitor panel displays the engine speed normally in the monitoring function. a For the monitoring function, see "Special functions of monitor panel". a Monitoring code: 01006 Engine speed
20-118 (1)
PC750, 800-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING FAN BELT TENSION
Testing The tension of this fan belt does not need to be tested or adjusted until when the belt is replaced.
Adjusting 1. Tighten adjustment screw (2) until it touches bracket (5).
Replacement 1. Open the engine compartment cover on the counterweight side.
2. Tighten adjustment screw (2) 2 more turns and secure it with locknut (1). 3 Locknut: 245.0 – 308.7 Nm {25.0 – 31.5 kgm}
2. Loosen locknut (1), and then fully loosen adjustment screw (2) toward the counterweight. 3. Insert a bar about 50 cm long in the hole (ø18) of tension pulley (3) and press tension pulley (3) toward the crank pulley to loosen the belt.
a If any clearance is made between adjustment screw (2) and bracket (5), eliminate it by the above procedure. a If the fan belts creak, adjust them by the above procedure.
4. Replace 4 V-belts (4) and return tension pulley (3) to their original positions. a Replace the 4 V-belts as a set.
PC750, 800-7
20-119 (1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING ALTERNATOR BELT TENSION Testing procedure 1. Open the engine compartment cover on the counterweight side.
Adjustment procedure a Adjust the belt according to the following procedure when the belt deflection is not normal.
2. Measure the belt deflection (a) when pushing a point midway between the alternator pulley and the drive pulley with the finger.
1. Loosen nuts and bolts (1), (2), (3) and (4) in this order.
a Deflection (a) when pressing force is approx. 58.8 N {approx. 6 kg}: 10 – 15 mm
2. Turn nut (5) to move alternator (6), and adjust the belt tension. a Nut (5): • It is moved to the side that belt is loosened when fastening it clockwise. • It is moved to the side that belt is tensioned when loosening it counterclockwise. a Test for breakage of each pulley, friction of V-ditch, friction of belt, and contact between belt and V-ditch. a Replace it with new belt if it was too stretched so that adjustability was lost, or cut and crack occurred. 3. Tighten nuts and bolts (4), (3), (2) and (1) in this order. a When the belt was replaced, readjust it after one-hour operation.
20-120 (1)
PC750, 800-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT Testing 1. Open the engine compartment cover on the control valve side and remove the cover of the air conditioner compressor belt.
3. Tighten nuts and bolts in the order of (4), (3), (2), and (1). a If the belts were replaced, adjust their tension again after operating the machine for 1 hour.
2. Press the intermediate point between the air conditioner compressor pulley and drive pulley with a finger and measure deflection (a). a Deflection (a) when pressing force is approx. 58.8 N {approx. 6 kg}: 10 – 15 mm
Adjusting a If the deflection is abnormal, adjust it according to the following procedure. 1. Loosen the bolts and nuts in the order of (1), (2), (3), and (4). 2. Rotate nut (5) to move compressor (6) and adjust the belt tension. a If nut (5) is • tightened clockwise, the belt is loosened. • loosened counterclockwise, the belt is tensed. a Check each pulley for breakage, check the V-grooves and V-belts for wear, and check that the V-grooves and V-belts are in good contact with each other. a If the belts are so lengthened that their tension cannot be adjusted any more or they have a cut or a crack, replace them.
PC750, 800-7
20-121 (1)
TESTING AND ADJUSTING
INSPECTION OF SWING CIRCLE BEARING CLEARANCE
INSPECTION OF SWING CIRCLE BEARING CLEARANCE a Inspection Device of Swing Circle Bearing Clearance Symbol
Part Number
J
Purchased
Part Name Dial gauge (with magnet)
3. Set the dial gauge J to the zero point. 4. Arrange the arm almost at right angles to the ground and lower the boom until the front leg of the machine body rises. a At the time, the front of the upper structure rises and its rear lowers.
a When measuring swing circle bearing clearance on a machine, follow the procedures below: a For the standard values, see STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, "Swing circle". 1. Fix the dial gauge J to the track frame (center frame) and bring the stylus to the outer race end face. a Set the dial gauge to the front or to the rear.
5. At the time, read the value on the dial gauge J. This value on the dial gauge indicates the swing circle bearing clearance. k During the measurement, never place hands and legs below the undercarriage.
2. Set the work equipment to the maximum reach and set the bucket tip to the height of the revolving frame lower face. a At the time, the front of the upper structure lowers and its rear rises.
20-122 (1)
6. Return the work equipment to the state in Paragraph 2 and make sure that the dial gauge J has returned to the zero point. If not, repeat Steps 2 to 5.
PC750, 800-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION TESTING 1. Travel the machine forward by the length of track on ground, keeping the engine at low idling, and stop the machine slowly. 2. Place wood bar [1] on the track shoe between second carrier roller (1) and third carrier roller (2). a L beam is recommended for bar [1], because of its deflection-free nature. 3. Measure max. clearance (a) between bar [1] and the track shoe. • Max. standard clearance (a): 10 – 30 mm
PC750, 800-7
ADJUSTING a If the track shoe tension is not proper, adjust it in the following manner. 1. When the tension is too strong Discharge grease by loosening valve (3).
k Do not loosen valve (3) by more than one turn, because grease will spurt due to its internal high pressure.
2. When the tension is too weak Add grease through grease fitting (4). a If the normal track shoe tension is not restored even after greasing, move the machine slowly back and forth.
20-123 (1)
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES
TESTING AND ADJUSTING
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES a Testing and adjusting instruments for work equipment, swing, and travel circuit oil pressures Symbol K
Part Number
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
MEASUREMENT a Mesure the work equipment, swing and travel circuit oil pressures under the following conditions: • Hydraulic oil temperature: Within operating temperature range a The work equipment, swing, and travel circuit oil pressures can be checked in the monitoring function of the monitor panel, too. (For the operating method, see "Special functions of monitor panel".) • Monitoring code: 01100 F pump pressure 01101 R pump pressure • The pump oil pressure is displayed in MPa {kg/cm2, PSI).
a Either quick coupler (2) or (4) can be used to measure the rear pump (No. 1 R + No. 2 R) circuit oil pressure. a The relief pressure of the boom LOWER circuit can be measured only in the front pump circuit. a The relief pressure of the bucket DUMP circuit can be measured only in the rear pump circuit. a The relief pressure of the swing circuit can be measured only in the front pump circuit. a Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}. • (1), (2) : Quick couplers for No. 1 pump
•
(3), (4) : Quick couplers for No. 2 pump
1. Preparation work
k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1) Open the pump compartment cover. 2) Connect oil pressure gauges [1] of hydraulic tester K to quick couplers (1) - (4) installed to the outlet of each pump of the circuit to be measured. a Either quick coupler (1) or (3) can be used to measure the front pump (No. 1 F + No. 2 F) circuit oil pressure.
20-124 (1)
PC750, 800-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES
2. Measuring work equipment circuit oil pressure 1) Measuring normal relief pressure i) Start the engine and set the working mode switch to the A-mode position. ii) Run the engine at high idling, relieve each cylinder singly at the stroke end, and measure the oil pressure. a The main relief valves of the right and left control valves relieve on the lowpressure setting side. a If the boom cylinder is relieved at the LOWER stroke end, the safety-suction valve on the boom head side of the right 4-spool control valve relieves on the lowpressure setting side (The set pressure of the safety-suction valve is lower than that of the main relief valve). 2) Measuring relief pressure during heavy lift operation i) Start the engine and set the working mode switch in the A-mode position. ii) Turn the heavy lift switch ON. iii) Run the engine at high idling, relieve the boom cylinder singly at the RAISE stroke end, and measure the oil pressure. a The heavy lift function operates only when the boom RAISE operation is performed singly. a The main relief valves of the right and left control valves relieve on the highpressure setting side. 3) Measuring relief pressure during machine push-up operation i) Start the engine and set the working mode switch in the A-mode position. ii) Turn the machine push-up switch ON. iii) Run the engine at high idling, relieve the boom cylinder singly at the LOWER stroke end, and measure the oil pressure. a Since the set pressure of the safety-suction valve on the boom head side of the right 4-spool valve rises higher than the set pressure of the main relief valve, the main relief valve relieves on the lowpressure setting side.
PC750, 800-7
3. Measuring swing circuit oil pressure 1) Start the engine and set the working mode switch in the A-mode position. 2) Turn the swing lock switch ON. 3) Run the engine at high idling, relieve the swing motor, and measure the oil pressure. a The safety valves of the front and rear swing motors relieve. (The set pressure of the safety valves is lower than that of the main relief valve.)
20-125 (1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES
4. Measuring travel circuit oil pressure 1) Start the engine and lock the travel mechanism.
k Put pin [2] between the sprocket and track frame to lock the travel mechanism securely.
ADJUSTING a Do not adjust any safety valve other than the swing motor safety valve. a When adjusting the main relief valves of the left 5-spool valve and right 4-spool valve, remove the control valve top cover. 1. Adjusting main relief valve (high-pressure setting) of left 5-spool control valve a If the work equipment oil pressure in the front pump circuit (during heavy lift operation) and the left travel oil pressure are abnormal, adjust the high-pressure setting side of main relief valve (5) of the left 5-spool control valve according to the following procedure.
2) Run the engine at high idling, relieve the travel motor, and measure the oil pressure. a The main relief valves of the right and left control valves relieve on the high-pressure setting side.
a The high pressure setting is the state in which the 2-stage relief solenoid valve is turned ON and the pilot pressure is applied to the changeover port. 1) Disconnect hose (6). 2) Loosen locknut (7) and set elbow (8) free. 3) Fix holder (9) and loosen locknut (10). 4) Turn holder (9) to adjust the pressure. a If the holder is • turned to the right, the pressure rises. • turned to the left, the pressure lowers. a Pressure changed by 1 turn of holder: 21.8 MPa {222 kg/cm2}
20-126 (1)
PC750, 800-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES
5) Fix holder (9) and tighten locknut (10). 3 Locknut: 93 – 123 Nm {9.5 – 12.5 kgm} a If the high-pressure setting side is adjusted, the low-pressure setting side changes. Accordingly, adjust the lowpressure setting side, too.
6) Fix elbow (8) and tighten locknut (7). 7) Connect hose (6). 8) After finishing adjustment, check the oil pressure again according to the above described measurement procedure.
2. Adjusting main relief valve (low-pressure setting) of left 5-spool control valve a If the work equipment oil pressure in the front pump circuit (during normal relief operation) is abnormal or the high-pressure setting side was adjusted, adjust the low-pressure setting side of main relief valve (5) of the left 5spool control valve according to the following procedure. a The low-pressure setting is the state in which the 2-stage relief solenoid valve is turned OFF and the pilot pressure is not applied to the changeover port. 1) Disconnect hose (6). 2) Loosen locknut (7) and set elbow (8) free. 3) Fix union (11) and loosen locknut (12). 4) Turn union (11) to adjust the pressure. a If the union is • turned to the right, the pressure rises. • turned to the left, the pressure lowers. a Pressure changed by 1 turn of union: 21.8 MPa {222 kg/cm2} 5) Fix union (11) and tighten locknut (12). 3 Locknut: 78 – 93 Nm {8.0 – 9.5 kgm}
6) Fix elbow (8) and tighten locknut (7). 7) Connect hose (6). 8) After finishing adjustment, check the oil pressure again according to the above described measurement procedure.
PC750, 800-7
20-127 (1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES
3. Adjusting main relief valve (high-pressure setting) of right 4-spool control valve a If the work equipment oil pressure in the rear pump circuit (during heavy lift operation) and the right travel oil pressure are abnormal, adjust the high-pressure setting side of main relief valve (13) of the right 4-spool control valve according to the following procedure.
•
(15): Safety valve of rear swing motor
1) Fix adjustment nut (16) and loosen locknut (17).
a Adjust the right 4-spool control valve similarly to the left 5-spool control valve. 4. Adjusting main relief valve (low-pressure setting) of right 4-spool control valve a If the work equipment oil pressure in the rear pump circuit (during normal relief operation) is abnormal or the high-pressure setting side was adjusted, adjust the low-pressure setting side of main relief valve (13) of the right 4-spool control valve according to the following procedure. a Adjust the right 4-spool control valve similarly to the left 5-spool control valve.
k Do not remove the adjustment nut. If it is removed, the internal parts may come off. 2) Turn adjustment nut (16) to adjust the pressure. a If the adjustment nut is • turned to the right, the pressure rises. • turned to the left, the pressure lowers. a Pressure changed by 1 turn of adjustment nut: 3.6 MPa {37 kg/cm2} 3) Fix adjustment nut (16) and tighten locknut (17). 3 Locknut: 147 –186 Nm {15 – 19 kgm}
5. Adjusting swing motor safety valve a If the relief pressure of the swing motor is abnormal, adjust safety valves (14) and (15) of the swing motor according to the following procedure. • (14): Safety valve of front swing motor
4) After finishing adjustment, check the oil pressure again according to the above described measurement procedure.
20-128 (1)
PC750, 800-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE a Instruments for testing and adjusting control circuit oil pressure Symbol L
Part Number
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
Adjusting a When adjusting the control relief valve, open the hydraulic tank rear cover. a If the control circuit oil pressure is abnormal, adjust control relief valve (2) according to the following procedure.
Measuring a Measure the control circuit oil pressure under the following condition. • Hydraulic oil temperature: Within operating range k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1. Open the pump compartment cover. 2. Connect oil pressure gauge [1] of hydraulic tester L to quick coupler (1) installed to the outlet of the control pump.
1. Remove cap (3). 2. Fix adjustment screw (4) and loosen locknut (5). 3. Turn adjustment screw (4) to adjust the pressure. a Turn the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE. • To DECREASE pressure, turn COUNTERCLOCKWISE. 4. Fix adjustment screw (4) and tighten locknut (5). 3 Locknut: 9.8 Nm {1 kgm}
3. Run the engine at high idling, set the work equipment/swing lever and travel lever in neutral, and measure the oil pressure.
5. After completion of adjustment, repeat the procedure in above to check the set pressure again.
PC750, 800-7
20-129 (1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE a Devices for inspecting and measuring piston pump control oil pressure Symbol 1
M
2 3 4
Part Number
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
799-401-2701
Differential pressure gauge
799-101-5220
Nipple (10 × 1.5 mm)
07002-11023
O-ring
799-401-3200
Adapter (Size: 03)
MEASUREMENT a Measure the piston pump control oil pressure under the following conditions: • Hydraulic oil temperature: Within the operating range k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1. Measuring TVC valve output pressure a Since the TVC valve output pressure varies with the discharge pressure of each pump, check that the oil pressure in the work equipment, swing, and travel circuits is normal before starting measurement. a Since the basic pressure of the TVC valve output pressure is the control circuit pressure, check that the control circuit pressure is normal before starting measurement. 1) Open the undercover of the No. 1 pump. 2) Remove oil pressure pickup plug (1) of the No. 1 front pump.
3) Install nipple M3 and connect oil pressure gauge [1] of hydraulic tester M1.
20-130 (1)
a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}.
4) Start the engine and set the working mode switch in the A-mode position. 5) Set all the control levers in neutral and measure the TVC valve output pressure under the following condition. i) Set all the control levers in neutral. ii) Run the engine at high idling and measure the output pressure. 6) Relieve the boom circuit by raising the boom (normally), and measure the TVC valve output pressure under the following condition. i) Turn the heavy lift switch OFF. ii) Run the engine at high idling, relieve the boom circuit by raising the boom, and measure the output pressure. 7) Turn the heavy lift switch ON, relieve the boom circuit by raising the boom, and measure the TVC valve output pressure under the following condition. i) Turn the heavy lift switch ON. ii) Run the engine at high idling, relieve the boom circuit by raising the boom, and measure the output pressure.
8) After finishing measurement, remove the measuring instruments and return the removed parts.
PC750, 800-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE
2. Measuring CO-NC valve output pressure 1) Open the undercover of the No. 2 pump. 2) Remove oil pressure pickup plugs (2) and (3) of the No. 2 pump. • (2): For front pump circuit • (3): For rear pump circuit
7) Drive the travel motor idle and measure the CO-NC valve output pressure under the following condition. i) Raise the track shoe to be measured by using the boom and arm. ii) Run the engine at high idling, drive the travel motor idle (with the lever at the stroke end), and measure the output pressure. 8) Turn the heavy lift switch ON, relieve the boom circuit by raising the boom, and measure the output pressure under the following condition. i) Turn the heavy lift switch ON. ii) Run the engine at high idling, relieve the boom circuit by raising the boom, and measure the output pressure.
3) Install nipple M3 and connect oil pressure gauge [1] of hydraulic tester M1. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}.
4) Start the engine and set the working mode switch in the A-mode position. 5) Set all the control levers in neutral and measure the CO-NC valve output pressure under the following condition. i) Set all the control levers in neutral. ii) Run the engine at high idling and measure the output pressure. 6) Relieve the boom circuit by raising the boom (normally) and measure the CO-NC valve output pressure under the following condition. i) Turn the heavy lift switch OFF. ii) Run the engine at high idling, relieve the boom circuit by raising the boom, and measure the output pressure.
PC750, 800-7
9) After finishing measurement, remove the measuring instruments and return the removed parts.
20-131 (1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE
3. Measuring jet sensor output differential pressure of left 5-spool control valve and right 4spool control valve 1) Remove oil pressure pickup plugs (4) and (5) under the left 5-spool control valve and oil pressure pickup plugs (6) and (7) under the right 4-spool control valve. • (4): High pressure side (Pt) of left 5spool control valve (F pump) • (5): Low pressure side (Pd) of left 5spool control valve (F pump) • (6): High pressure side (Pt) of right 4spool control valve (R pump) • (7): Low pressure side (Pd) of right 4spool control valve (R pump) a The jet sensor output differential pressure may be measured at the inlet hose of the No. 1 pump by using adapter M4 and nipple M3.
2) Install nipple [2] of hydraulic tester M1 and connect it to differential pressure gauge M2 or oil pressure gauge [1]. a When using differential pressure gauge: Connect the high pressure (Pt) to the high pressure side (back side) of the differential pressure gauge and connect the low pressure (Pd) to the low pressure side (lower side). Since the differential pressure gauge needs DC 12 V, connect 1 battery to it. a When using pressure gauge: Connect the pressure gauge of 5.9 MPa {60 kg/cm 2 } to the high pressure side (Pt) and connect the pressure gauge of 2.5 MPa {25 kg/cm2} to the low pressure side (Pd).
20-132 (1)
3) Start the engine and set the working mode switch in the A-mode position. 4) Set all the control levers in neutral and measure the jet sensor output differential pressure under the following condition. i) Set all the control levers in neutral. ii) Run the engine at high idling and measure the output differential pressure. a Jet sensor output differential pressure = High pressure (Pt) – Low pressure (Pd) 5) Drive the travel motor idle and measure the jet sensor output differential pressure under the following condition. i) Raise the track shoe to be measured by using the boom and arm. ii) Run the engine at high idling, drive the travel motor idle, and measure the output differential pressure. a Jet sensor output differential pressure = High pressure (Pt) – Low pressure (Pd)
PC750, 800-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE
6) After finishing measurement, remove the measuring instruments and return the removed parts.
1) Fix adjustment screw (9) and loosen locknut (10). 2) Turn adjustment screw (9) to adjust the pressure. a If the adjustment screw is • turned to the right, the pressure rises. • turned to the left, the pressure lowers. a Pressure changed by 1 turn of adjustment screw: 0.34 MPa {3.5 kg/cm2} 3) Fix adjustment screw (9) and tighten locknut (10). 3 Locknut: 5.9 – 9.8 Nm {0.6 – 1.0 kgm}
ADJUSTING 1. Adjusting TVC valve a When adjusting the TVC valve, open the pump compartment cover. a If the TVC valve output pressure is abnormal, adjust TVC valve (8) of the No. 1 pump according to the following procedure.
4) After finishing adjustment, check the oil pressure again according to the above described measurement procedure. 2. Adjusting CO-NC valve a When adjusting the CO valve side of the CONC valve, remove the No. 1 pump undercover. When adjusting the NC valve side, open the pump compartment cover. a If the CO-NC valve output pressure is abnormal, adjust CO valves (11) and (12) and NC valves (13) and (14) of the No. 1 pump according to the following procedure. • (11): Front CO valve of No. 1 pump • (12): Rear CO valve of No. 1 pump
PC750, 800-7
20-133 (1)
TESTING AND ADJUSTING
• •
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE
(13): Front NC valve of No. 1 pump (14): Rear NC valve of No. 1 pump
1) Adjusting CO valve side i) Fix adjustment screw (15) and loosen locknut (16). ii) Turn adjustment screw (15) to adjust the pressure. a If the adjustment screw is • turned to the right, the pressure rises. • turned to the left, the pressure lowers. a Pressure changed by 1 turn of adjustment screw: 4.05 MPa {41.25 kg/cm2} iii) Fix adjustment screw (15) and tighten locknut (16). 3 Locknut: 5.9 – 9.8 Nm {0.6 – 1.0 kgm}
2) Adjusting NC valve side i) Fix adjustment screw (17) and loosen locknut (18). ii) Turn adjustment screw (17) to adjust the pressure. a If the adjustment screw is • turned to the right, the pressure rises. • turned to the left, the pressure lowers. a Pressure changed by 1 turn of adjustment screw: 0.39 MPa {4.0 kg/cm2} iii) Fix adjustment screw (17) and tighten locknut (18). 3 Locknut: 5.9 – 9.8 Nm {0.6 – 1.0 kgm}
iv) After finishing adjustment, check the oil pressure again according to the above described measurement procedure. 3. Adjusting jet sensors of left 5-spool control valve and right 4-spool control valve a If the jet sensor output differential pressure of the left 5-spool control valve or right 4spool control valve is abnormal, adjust jet sensor relief valves (19) and (20) according to the following procedure. • (19): Jet sensor relief valve of left 5-spool control valve • (20): Jet sensor relief valve of right 4-spool control valve
iv) After finishing adjustment, check the oil pressure again according to the above described measurement procedure.
20-134 (1)
PC750, 800-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE
1) Fix adjustment screw (21) and loosen locknut (22). 2) Turn adjustment screw (21) to adjust the pressure. a If the adjustment screw is • turned to the right, the pressure rises. • turned to the left, the pressure lowers. a Pressure changed by 1 turn of adjustment screw: 0.288 MPa {2.94 kg/cm2} 3) Fix adjustment screw (21) and tighten locknut (22). 3 Locknut: 59 – 78 Nm {6 – 8 kgm}
4) After finishing adjustment, check the oil pressure again according to the above described measurement procedure.
PC750, 800-7
20-135 (1)
TESTING AND ADJUSTING
INSPECTION OF SERVO PISTON STROKE
INSPECTION OF SERVO PISTON STROKE a Devices for inspecting and measuring piston stroke control oil pressure Symbol
N
1 2
Part Number
Part Name
708-25-14140
Cap
07000-B2065
O-ring
566-98-41120
Disc gauge
a After checking that the rod moves smoothly, keep it at the position where it is most protruded. 5) Stop the engine and measure the size of the rod protrusion a2. 6) Calculate the servo piston stroke b from the measured size. a Servo piston stroke b = a2 – a1 a Standard stroke b: 9.37 mm
a When the NC valve output pressure is normal but the pump performance is considered inappropriate, inspect the acceptability of the servo valve and piston according to the following procedures: 1. Preparation of tool Drill a through hole PT1/4 in the center of the cap N1 and screw the disc gauge N2 in the hole. a Prepare the cap for the side where the spring of the hydraulic pump servo piston is fitted.
7) After finishing testing, remove the testing tools and return the removed parts.
2. Measurement of stroke 1) Remove the cap and the shim of the servo valve on the measuring side. a Since the cap is pressed with the spring, remove the cap carefully with the long bolt (01016-31070, etc.) and the nut so that the cap does not jump out. 2) Mount the measuring tools N, on the servo piston together with the removed shim. a Be careful so that the shim is not caught in the bolt threads. 3) Push in the rods of the measuring tools, N, fully and measure the size of the protrusion a1. 4) Start the engine, keep it at full throttle and move the track shoe without load or swing it without load. a Operate the lever to the full stroke. a During the measurement, press the rod with hand and check at the same time that the rod moves smoothly as the control lever changes the stroke.
20-136 (1)
3. Judgment of servo valve a If the servo piston stroke is abnormal, remove the servo valve, servo piston cap, and spring, and check that you can move the servo piston smoothly before judging the condition of the servo valve. 1) When servo piston stroke is normal: Servo valve is normal. 2) When servo piston stroke is abnormal: • Servo piston moves smoothly; Servo valve is abnormal. • Servo piston does not move smoothly; Servo valve is normal.
PC750, 800-7
TESTING AND ADJUSTING
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE a Devices for measuring PPC valve output pressure Symbol
P
1 2
Part Number
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
799-401-3200
Adapter (Size: 03)
a Measure the PPC valve output pressure under the following conditions: • Hydraulic oil temperature: Within operating range k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1. Remove the control valve top cover. 2. Disconnect hose (1) of the PPC circuit to be measured. Install adapter P2 and connect the hose again. a For the hose to be disconnected, see the connection diagram on the next page.
4. Run the engine at high idling, operate the control lever of the PPC circuit to be measured, and measure the oil pressure. a Move the control lever to the stroke end. a Condition of actuator to be measured • When measuring the pressure for the work equipment, move each cylinder to the stroke end. • When measuring the pressure for swing, turn the swing lock switch ON. • When measuring the pressure for travel, put pin [3] between the sprocket and track frame to lock the track shoe.
3. Install nipple [1] of hydraulic tester P1 and connect it to oil pressure gauge [2]. a Use a pressure gauge of 5.9 MPa {60 kg/cm2} a The figure shows the measuring instruments installed to the right travel (reverse) circuit of the left 5-spool control valve.
5. After the measurement, remove the measuring devices and return the valve to the original state. PC750, 800-7
20-137 (1)
TESTING AND ADJUSTING
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
Connection diagram of pilot piping (PPC-Solenoid-OLSS circuit)
20-138 (1)
PC750, 800-7
TESTING AND ADJUSTING
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
a The colors in ( ) in the figure are the colors of the tapes wound onto the hoses.
PC750, 800-7
20-139 (1)
MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTOR VALVE
TESTING AND ADJUSTING
MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTOR VALVE a Devices for measuring outlet pressures of solenoid valve, swing PPC shuttle valve, and swing priority selector valve Symbol
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
2
799-401-3200
Adapter (Size: 03)
3
799-401-3300
Adapter (Size: 04)
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
1
Q
Part Number
4
a Measure the outlet pressures of solenoid valve, swing PPC shuttle valve, and swing priority selector valve under the following condition. • Hydraulic oil temperature: Within operating range k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1. Measuring outlet pressure of solenoid valve 1) Disconnect outlet hoses (1) – (8) of the solenoid valves to be measured. Install adapter Q2 or Q3 and connect the hoses again. a When measuring the safety lock solenoid valve, remove the operator's cab undercover (the 2nd piece on the front side). a If the solenoid valve side of a hose is connected by a quick coupler, disconnect the other end of the hose (See the connection diagram in MEASURING PPC VALVE OUTPUT PRESSURE). • (1): Safety lock solenoid valve
20-140 (1)
• • • • •
(2): Travel speed shifting solenoid valve (3): Machine push-up solenoid valve (4): 2-stage relief solenoid valve (5): Travel junction solenoid valve (6): CO cancel solenoid valve
•
(7): Swing holding brake solenoid valve
•
(8): Swing priority solenoid valve
PC750, 800-7
TESTING AND ADJUSTING
MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTOR VALVE
2) Install the nipple (R1/8) of hydraulic tester Q1 or nipple Q4 (10 × 1.25 mm) and connect it to oil pressure gauge [1]. a Use a pressure gauge of 5.9 MPa {60 kg/cm2} a The following figure shows the measuring devices installed to the outlet hose of the safety lock solenoid valve.
3) Run the engine at high idling, set the condition or operate the control levers as shown in the table, and measure the output pressure. a When operating the work equipmentswing or travel control lever, operate it finely to a degree that the PPC oil pressure switch is turned ON. a If the solenoid valve outlet pressure is as shown in the table, the solenoid valve is normal.
4) After finishing measurement, remove the measuring instruments and return the removed parts.
PC750, 800-7
20-141 (1)
TESTING AND ADJUSTING
MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTOR VALVE
Measurement conditions for solenoid valve a The measurement conditions in the following table are for measuring the solenoid valve outlet pressure and they are a part of the operating condition of each solenoid valve. No.
1
2
3
4
5
6
7
8
Solenoid valve
Safety lock
Travel speed shifting
Machine push-up
2-stage relief
Travel junction
CO cancel
Swing holding brake
Swing priority (See note)
Measurement condition
Operation of machine
Operation Oil pressure of (MPa {kg/cm2}) solenoid
• Set safety lock lever in LOCK position.
Basic pressure circuit to PPC valve is closed.
OFF
0 {0}
• Set safety lock lever in FREE position.
Basic pressure circuit to PPC valve is opened.
ON
Min. 2.74 {Min. 28}
• Set travel speed switch in Lo position.
Swash plate angle of travel motor is set to maximum.
OFF
0 {0}
• Set travel speed switch in Hi position.
Swash plate angle of travel motor is set to minimum.
ON
Min. 2.74 {Min. 28}
• Turn machine push-up switch ON.
Boom LOWER safety valve is set to high pressure.
OFF
0 {0}
• Turn machine push-up switch OFF.
Boom LOWER safety valve is set to low pressure.
ON
Min. 2.74 {Min. 28}
• Turn heavy lift switch OFF.
Main relief valve is set to low pressure.
OFF
0 {0}
• Turn heavy lift switch ON and raise boom singly. • Operate travel lever.
Main relief valve is set to high pressure.
ON
Min. 2.74 {Min. 28}
• Set all control levers in NEUTRAL position.
F pump circuit and R pump circuit are separated.
OFF
0 {0}
• Operate right and left travel levers and work equipmentswing lever simultaneously.
F pump circuit and R pump circuit are merged.
ON
Min. 2.74 {Min. 28}
• Set working mode switch in EPump CO function is turned mode. ON. • Turn heavy lift switch OFF.
OFF
0 {0}
• Set working mode switch in Amode. Pump CO function is turned • Turn heavy lift switch ON. OFF. • Operate travel lever.
ON
Min. 2.74 {Min. 28}
• Turn swing lock switch ON. • Measure about 10 seconds after work equipment-swing control lever is set in NEUTRAL position.
Swing holding brake is applied.
OFF
0 {0}
• Turn swing lock switch OFF and operate work equipmentswing control lever.
Swing holding brake is released.
ON
Min. 2.74 {Min. 28}
• Turn swing priority switch OFF and raise boom.
Swing priority function is turned OFF.
OFF
Min. 2.35 {Min. 24}
• Turn swing priority switch ON and raise boom.
Swing priority function is turned ON.
ON
0 {0}
NOTE: The inlet pressure of the swing priority solenoid valve is the boom RAISE PPC circuit pressure. Accordingly, when measuring the outlet pressure, move the boom control lever to the RAISE stroke end (The boom cylinder may be at the RAISE stroke end).
20-142 (1)
PC750, 800-7
TESTING AND ADJUSTING
MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTOR VALVE
2. Measuring outlet pressure of swing PPC shuttle valve 1) Disconnect outlet hose (9) of the swing PPC shuttle valve. Install adapter Q2 and connect the hose again. a When measuring the swing PPC shuttle valve, remove the control valve top cover.
2) Install the nipple (R1/8) of hydraulic tester Q1 and connect it to oil pressure gauge [1]. a Use a pressure gauge of 5.9 MPa {60 kg/cm2} 3) Run the engine at high idling, set the condition or operate the control levers as shown in the table, and measure the output pressure. a If the swing PPC shuttle valve outlet pressure is as shown in the table, the PPC shuttle valve is normal. Measurement condition Neutral Left work Position for equipment swinging to left control lever Position for swinging to right
Oil pressure (MPa {kg/cm2})
3. Measuring outlet pressure of swing priority selector valve 1) Disconnect outlet hoses (10) and (11) of the swing priority selector valve. Install adapters Q2 and connect the hoses again. a When measuring the swing priority selector valve, remove the control valve top cover. • (10): Port A1 (For swing) • (11): Port A2 (For arm Lo and bucket Hi)
2) Install the nipple (R1/8) of hydraulic tester Q1 and connect it to oil pressure gauge [1]. a Use a pressure gauge of 58.8 MPa {600 kg/cm2} k Since the outlet pressure of the swing priority selector valve is the same as the main pump pressure, take care not to connect the oil pressure gauge for low pressure.
0 {0} Min. 2.35 {Min. 24} Min. 2.35 {Min. 24}
4) After finishing measurement, remove the measuring instruments and return the removed parts. PC750, 800-7
20-143 (1)
TESTING AND ADJUSTING
MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTOR VALVE
3) Run the engine at high idling, set the condition or operate the control levers as shown in the table, and measure the output pressure. a If the swing priority selector valve outlet pressure is as shown in the table, the swing priority selector valve is normal. • Port A1 (For swing) Measurement conditions
Oil pressure (MPa {kg/cm2})
Swing priority switch: OFF Neutral Right work equipment Position for control lever raising boom
0 {0} Same as main pump pressure
Swing priority switch: ON Neutral Right work equipment Position for raiscontrol lever ing boom
•
0 {0} 0 {0}
Port A2 (For arm Hi and bucket Lo) Measurement conditions Neutral
Left work Position for equipment swinging to left control lever Position for swinging to right
Oil pressure (MPa {kg/cm2}) 0 {0} Same as main pump pressure Same as main pump pressure
4) After finishing measurement, remove the measuring instruments and return the removed parts.
20-144 (1)
PC750, 800-7
TESTING AND ADJUSTING
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE a If there is excessive play at the tip of the work equipment or swing lever, adjust at the PPC valve end as follows. • Standard lever play a: 0.5 – 3 mm at point 200 mm from rotating center of lever (forward and reverse, and left and right) 1. Remove boot (1). 2. Loosen locknut (2), then turn disc (3) to adjust the play of the lever. a When doing this, do not move the piston. 3. Secure disc (3) in position, then tighten locknut (2) to the specified torque. 3 Locknut : 98.07 – 127.49 Nm {10 – 13 kgm} 4. Install boot (1).
PC750, 800-7
20-145 (1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING TRAVEL DEVIATION
TESTING AND ADJUSTING TRAVEL DEVIATION Measuring a Measure on a hard and flat place. 1. Start the engine and set the work equipment in the travel position. a To set the work equipment in the travel position, extend the bucket and arm cylinders fully and set the boom angle to 45 degrees. 2. Set the working mode switch to the A-mode position and set the travel speed switch to the Lo position. 3. Run up for 10 m with the engine speed at high idling and continue travel under the same condition for 20 m and measure the deviation a. a At this time, install an oil pressure gauge and measure the pump discharge pressure, too, (or monitor the pump discharge pressure with the monitor panel).
20-146 (1)
PC750, 800-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING TRAVEL DEVIATION
Adjusting a If the travel deviation is abnormal, adjust the thickness of the shim at the servo piston according to the following procedure.
•
No. 1 pump
•
No. 2 pump
1. Determine where to add a shim from the direction of the travel deviation. a Adjustment method
•
•
When machine deviates to left
When machine deviates to right
Add shim on front pump side (b).
Add shim on rear pump side (c).
No. 1 pump
No. 2 pump 3. Add shim (2) according to the deviation and tighten bolt (1). a Limit the thickness of the added shim to 3 mm for each pump. 3 Bolt: 59 – 74 Nm {6.0 – 7.5 kgm} a Travel deviation and thickness of added shim
2. Loosen 4 bolts (1) on the side to adjust the shim. a Since the shim is of split type, you do not need to remove the cap. a Since the cap is pressed by the spring, loosen the bolt to a degree that you can insert the shim. 4. After finishing adjustment, check the travel deviation again according to the above described procedure.
PC750, 800-7
20-147 (1)
TESTING AND ADJUSTING
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT a If there is any hydraulic drift in the work equipment (cylinders), check in the following manner to determine if the cause is in the cylinder packing or in the control valve.
2. Inspection of arm cylinder 1) Operate the arm cylinder to move the arm to the position 100 mm before the digging stroke end, and stop the engine.
1. Inspection of boom and bucket cylinders 1) Set the work equipment in the same posture as when measuring hydraulic drift, and stop the engine. a Fill the bucket with earth or apply the rated load to the bucket.
2) Operate the control lever to the RAISE position or the bucket control lever to the CURL position. • If the lowering speed increases, the cylinder packing is defective. • If there is no change, the control valve is defective. a Operate the control lever with the engine starting switch in the ON position. a If pressure in the accumulator has dropped, run the engine for approx. 10 seconds to charge the accumulator again.
20-148 (1)
2) Operate the arm control lever to move the arm to the digging side. • If the lowering speed increases, the cylinder packing is defective. • If there is no change, the control valve is defective. a Operate the control lever with the engine starting switch in the ON position. a If pressure in the accumulator has dropped, run the engine for approx. 10 seconds to charge the accumulator again. [Reference]If the cause of the hydraulic drift is in the defective packing, and the above operation is carried out, downward movement is accelerated for the following reasons. 1) If the work equipment is set to the above posture (holding pressure applied to the bottom end), the oil at the bottom end leaks to the head end. However, the volume at the head end is small than the volume at the bottom end by the volume of the rod end, so the internal pressure at the head end increases because of the oil flowing in from the bottom end. 2) When the internal pressure at the head end increases, the pressure at the bottom end also rises in proportion to this. The balance is maintained at a certain pressure (this differs according to the amount of leakage) by repeating this procedure. 3) When the pressure is balanced, the downward movement becomes slower. If the lever is then operated according to the procedure given above, the circuit at the head end is opened to the drain circuit (the bottom end is closed by the check valve), so the oil at the head end flows to the drain circuit and the downward movement becomes faster. PC750, 800-7
TESTING AND ADJUSTING
MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE a Measuring device for oil leakage Symbol
Part Number
R
Purchased
Part Name Measuring cylinder
a Measure the oil leakage under the following condition. • Hydraulic oil temperature: Within operating range 1. Measuring leakage from boom cylinder 1) Run the engine and raise the boom to the stroke end.
k Referring to RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT, release the residual pressure from the piping on the boom cylinder head side (Operate the lever only in the RAISE direction, however). 2) Disconnect hoses (1) on the cylinder head side and block it with a flange.
2. Measuring leakage from arm cylinder 1) Run the engine and move in the arm to the stroke end.
k Referring to RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT, release the residual pressure from the piping on the arm cylinder head side (Operate the lever only in the IN direction, however). 2) Disconnect hose (2) on the cylinder head side and block it with a flange. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose. 07379-01470 (Flange #14)
k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose. 07379-01260 (Flange #12)
3) Run the engine at high idling and relieve the arm cylinder by operating the arm control lever in the IN direction.
3) Run the engine at high idling and relieve the boom cylinder by operating the boom control lever in the RAISE direction.
k Take care not to operate the arm control lever in the OUT direction. 4) Start measuring the oil leakage 30 seconds after the arm cylinder is relieved and measure for 1 minute. 5) After finishing measurement, return the parts.
k Take care not to operate the boom control lever in the LOWER direction. 4) Start measuring the oil leakage 30 seconds after the boom cylinder is relieved and measure for 1 minute. 5) After finishing measurement, return the parts.
PC750, 800-7
20-149 (1)
TESTING AND ADJUSTING
3. Measuring leakage from bucket cylinder 1) Run the engine and curl the bucket to the stroke end.
k Referring to RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT, release the residual pressure from the piping on the bucket cylinder head side (Operate the lever only in the CURL direction, however). 2) Disconnect hose (3) on the cylinder head side and block it with a flange.
MEASURING OIL LEAKAGE
4. Measuring leakage from swing motor 1) Disconnect drain hoses (4) and (5) and plug them. a Use the following parts to block the hoses. 07376-70522 (Plug #05) • (4): Drain hose of front swing motor
k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose. 07379-01470 (Flange #14)
•
(5): Drain hose of rear swing motor
3) Run the engine at high idling and relieve the bucket cylinder by operating the bucket control lever in the CURL direction.
k Take care not to operate the bucket control lever in the DUMP direction. 4) Start measuring the oil leakage 30 seconds after the bucket cylinder is relieved and measure for 1 minute. 5) After finishing measurement, return the parts.
20-150 (1)
2) Turn the swing lock switch ON. 3) Run the engine at high idling and relieve the swing circuit and measure the oil leakage. a Start measuring the oil leakage 30 seconds after the swing motor circuit is relieved and measure for 1 minute. a After measuring 1 time, swing the upper structure 180° and measure again. 4) After finishing measurement, return the parts.
PC750, 800-7
TESTING AND ADJUSTING
5. Measuring leakage from travel motor 1) Remove the travel motor cover.
4 Travel motor cover: 120 kg 2) Start the engine and lock the travel mechanism.
k Set pin [1] between the sprocket and track frame to lock the travel mechanism securely.
MEASURING OIL LEAKAGE
6. Measuring leakage from center swivel joint 1) Put block [1] between the sprocket and frame to lock the travel motor of the port to be inspected, and then stop the engine.
k Loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the tank. a Inspection ports, travel directions, and measurement ports (See figure on following parts) Inspection port
Travel direction
Measurement ports
A
Right reverse
T and B
B
Right forward
A and P
P
Change of speed
B and C
C
Left reverse
P and D
D
Left forward
C and T
T
Drain
3) Disconnect drain hose (6) of the travel motor and plug it. a Use the following part to block the hose. 07376-70522 (Plug #05)
4) Run the engine at high idling and relieve the travel circuit and measure the oil leakage.
k Since wrong operation of the levers can cause an accident, make signs and confirmation securely. a Start measuring the oil leakage 30 seconds after the travel motor circuit is relieved and measure for 1 minute. a Measure the oil leakage several times, moving the motor little by little (changing the positions of the valve plate and cylinder and those of the cylinder and piston). 5) After finishing measurement, return the parts.
PC750, 800-7
20-151 (1)
TESTING AND ADJUSTING
2) Disconnect the hoses of the upper and lower measurement ports of the inspection port from the top of the swivel joint and block them. a For combination of the inspection port and measurement ports, see the above table. a Use the following parts to block the hoses. • Ports A, B, C, and D: 07379-01044 (Flange #10) • Port P: 07376-70315 (Plug #03) • Port T: 07376-70522 (Plug #05)
20-152 (1)
MEASURING OIL LEAKAGE
3) Run the engine at high idling and measure the oil leakage through the measurement ports. a When measuring ports A, B, C, and D, relieve the travel motor slowly in the revolving direction (See the table on the last page). a When measuring port P, set the travel speed shifting switch in the Hi position. 4) Start measuring the oil leakage 1 minute after the center swivel joint is relieved and measure for 1 minute.
PC750, 800-7
TESTING AND ADJUSTING
RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT
RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT 1. Release of residual pressure from hydraulic tank
k The hydraulic tank is enclosed and pressurized. When removing a hose or a plug connected to the hydraulic tank, release the residual pressure from the hydraulic tank according to the following procedure. 1) Lower the work equipment to the ground in a stable posture and stop the engine. 2) Slowly loosen oil filler cap (1) of the hydraulic tank to release the air from the tank.
3. Release of residual pressure from swing motor circuit a Release the residual pressure from the swing motor circuit by performing the procedure for 2. Release of residual pressure from hydraulic cylinder circuit. 4. Release of residual pressure from travel motor circuit a Since the control valve spool of the travel motor is open, release the residual pressure from the travel motor circuit by performing the procedure for 1. Release of residual pressure from hydraulic tank.
2. Release of residual pressure from hydraulic cylinder circuit
k When disconnecting the piping between a hydraulic cylinder and the control valve, release the residual pressure from the piping according to the following procedure. 1) Referring to 1. Release of residual pressure from hydraulic tank, release the residual pressure from the hydraulic tank. a Leave the oil filler cap of the hydraulic tank removed. 2) Turn the starting switch to the ON position and set the safety lock lever in the FREE position, and then operate the work equipment control levers on both sides forward, backward, to the right, and to the left. a The control valve is driven with the pressure in the accumulator. If it is operated 2 – 3 times, the pressure lowers. 3) Start the engine and run it at low idling for 5 seconds to heighten the pressure in the accumulator. 4) Repeat above steps 2) and 3) 2 – 3 times, and all residual pressure is released from the piping.
PC750, 800-7
20-153 (1)
TESTING AND ADJUSTING
BLEEDING AIR FROM EACH PART
BLEEDING AIR FROM EACH PART Air bleeding item
Contents of work • Replacement of hydraulic oil • Cleaning of strainer • Replacement of return filter element • Replacement or repair of hydraulic pump • Removal of suction piping • Replacement or repair of control valve • Removal of control valve piping • Replacement or repair of cylinder • Removal of cylinder piping • Replacement or repair of swing motor • Removal of swing motor piping • Replacement or repair of travel motor • Removal of travel motor piping • Replacement or repair of swivel joint • Removal of swivel joint piping
1 Bleeding air from hydraulic pump q
2 Starting engine q
Air bleeding procedure 3 4 5 6 Bleeding Checking Bleeding Bleeding oil level air from air from air from and starttravel swing cylinder ing work motor motor q q q q (See note) (See note)
q q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
NOTE: Bleed air from the swing motor and travel motor only when the oil was drained from the motor cases. 1. Bleeding air from hydraulic pump 1) Loosen air bleeders (1) and (2) by 4 turns and remove the oil filler cap of the hydraulic tank. a Leave the machine under the above condition for 10 minutes or more. 2) After oil flows out of bleeders (1) and (2), run the engine at low idling. a If the engine water temperature is low and the automatic warm-up operation is started, stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial (Set the starting switch in the ON position and hold the fuel control dial in the MAX position for 3 seconds, and the automatic warm-up operation is reset). a Set the safety lock lever in the LOCK position so that you will not operate a lever by mistake.
20-154 (1)
3) After clear oil flows out of bleeders (1) and (2), tighten the bleeders. 3 Bleeder: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
PC750, 800-7
TESTING AND ADJUSTING
2. Starting engine When running the engine after performing step 1, keep its speed at low idling for 10 minutes. 3. Bleeding air from cylinder a If a cylinder was replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder does not move to the lowering stroke end, if it is installed to the work equipment. 1) Run the engine at low idling for about 5 minutes. 2) Running the engine at low idling, raise and lower the boom 4 - 5 times. a Stop the piston rod about 100 mm before each stroke end. Do not relieve the oil. 3) Running the engine at high idling, perform step 2). 4) Running the engine at low idling, move the piston rod to the stroke end and relieve the oil. 5) Bleed air from the arm cylinder and bucket cylinder according to steps 2) – 4). 4. Bleeding air from swing motor 1) Motor unit a Bleed air from the motor unit according to the following procedure. i) Run the engine at low idling. ii) Swing to the right and left slowly to bleed air. 2) Parking brake circuit a Normally, air in the parking brake circuit is bled by swinging the machine in step 1). If you feel dragging of the brake during swinging operation, however, bleed air from the parking brake circuit according to the following procedure. i) Loosen the adapters of brake hoses (3) and (4) and start the engine. ii) Run the engine at low idling and set the swing holding brake release switch to the RELEASE and NORMAL positions repeatedly. After clear oil oozes out, tighten the adapters.
PC750, 800-7
BLEEDING AIR FROM EACH PART
•
Front swing motor
•
Rear swing motor
3) Safety valve circuit a Normally, air in the safety valve circuit is bled by swinging the machine in step 1). If abnormal sound comes out from around the safety valve during swinging operation, however, bleed air from the safety valve circuit according to the following procedure. i) Loosen plugs (5) and (6) and start the engine. ii) Run the engine at low idling. After clear oil oozes out, tighten the plugs. 3 Plug: 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
20-155 (1)
TESTING AND ADJUSTING
BLEEDING AIR FROM EACH PART
5. Bleeding air from travel motor 1) Remove the travel motor cover.
4 Travel motor cover: 120 kg 2) Loosen bleeder (7) by 1 turn and start the engine. a Do not loosen the bleeder more than 1 turn. 3) Run the engine at low idling and repeat the forward and reverse travel operations 4 - 5 times. After clear oil flows out, tighten the bleeder. a Limit the operation of the lever to a degree that the machine starts traveling. 3 Bleeder: 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
6. Checking oil level and starting work 1) Run the engine, retract the arm cylinder and bucket cylinder to the stroke ends, lower the work equipment to the ground, and stop the engine.
2) Check the oil level by the sight gauge at the back of the hydraulic tank. a If the oil level is between lines H and L, it is normal. a If the oil level is below line L, add new oil.
20-156 (1)
PC750, 800-7
TESTING AND ADJUSTING
INSPECTION PROCEDURES FOR DIODE
INSPECTION PROCEDURES FOR DIODE a Check an assembled-type diode (8 pins) and single diode (2 pins) in the following manner. a The continuity direction of an assembled-type diode is as shown in the diagram below.
3) Determine if a specific diode is good or no good with the indicated value. • No change in the indicated value: No continuity (defective). • Change in the indicated value: Continuity established (normal) (Note) Note: A silicon diode shows a value between 400 and 600.
a The continuity direction of a single diode is shown on the diode surface.
1. When using digital type circuit tester 1) Switch the testing mode to diode range and confirm the indicated value. a Voltage of the battery inside is displayed with conventional circuit testers. 2) Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of diode, and confirm the displayed value.
PC750, 800-7
2. When using analog type circuit tester 1) Switch the testing mode to resistance range. 2) Check the needle swing in case of the following connections. i) Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of diode. ii) Put the red probe (+) of the test lead to the cathode (N) and the black probe (–) to the anode of diode. 3) Determine if a specific diode is good or no good by the way the needle swings. • If the needle does not swing in Case i), but swings in Case ii): Normal (but the breadth of swing (i.e. resistance value) will differ depending on a circuit tester type or a selected measurement range) • If the needle swings in either case of i) and ii): Defective (short-circuited internally) • If the needle does not swing in any case of i) and ii): Defective (short-circuited internally)
20-157 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
SPECIAL FUNCTION OF MONITOR PANEL
[1] Figure input switch 1 [2] Figure input switch 2 [3] Figure input switch 3 [4] Figure input switch 4 [5] Figure input switch 5
20-158 (1)
[6] Figure input switch 6 [7] Figure input switch 7 [8] Figure input switch 8 [9] Figure input switch 9 [0] Figure input switch 0
[ [ [ [
] Return switch ] Upward move switch ] Downward move switch ] Input confirmation switch
PC750, 800-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
Monitor panel functions - conventional and special The monitor panel is provided with conventional and special functions, and various kind of information are shown in the display. Display items consists of automatic display items that are preset in the monitor panel and others that are shown by switch operations. 1. Conventional function: Operator's Menu This is a function by which an operator can set or show displays by switch operations. The display contents are those which are normally shown. 2. Special function: Service Menu This is a function by which a service mechanic can set or show displays by special switch operations. The display contents are those which are not normally shown. It is mainly used for inspection, adjustment, troubleshooting or special setting of machines.
Operator's Menu 1
Function for showing KOMATSU logo
2
Function for check before starting
3
Function for showing machine maintenance
4
Service Menu 14
Function for monitoring [01]
15
Function for failure history [02]
Function for showing caution items
16
Function for maintenance history [03]
5
Function for confirming working mode and travel speed
17
Function for maintenance mode change [04]
18
Function for recording phone No. [05]
6
Function for display of ordinary items
7
Function for adjusting display luminance and contrast
8
Function for confirming maintenance information
9
Function for showing service meter reading
10
Function for checking display LCD
11
Function for showing occurrence of caution item
12
Function for showing users' code No.
13
Function for showing error code No. and failure code No.
PC750, 800-7
Electrical system Mechanical system
Mode with key on 19
Function for initial value setting and default [06]
Language Unit Wiper select
20
Function for adjustment [07]
21
Function for reduced cylinder mode operation [08]
20-159 (2)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
Operation of Operator's Menu and Display (Outline) a This section introduces only the outline of the operator's menu. For details on the contents and operation steps of each menu, refer to the operation and maintenance manual or the chapter of "STRUCTURE AND FUNCTION" in this shop manual. 1. Function for showing KOMATSU logo When the engine starting switch is turned ON, KOMATSU logo is shown for two seconds.
2. Function for machine inspection before starting day's work Following the KOMATSU logo, the display of machine inspection before starting day's work is shown for 2 seconds.
3. Function for machine maintenance Following the display of machine inspection before starting day's work, the maintenance mark appears for 30 seconds, if there is an oil filter whose maintenance time is approaching or has just passed. a This display appears only when the maintenance function is set.
4. Function for showing precaution items If there is any item of machine inspection before starting day's work that indicates some abnormality, a corresponding symbol mark is shown after the display of machine inspection before starting day's work.
20-160 (1)
PC750, 800-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
5. Function for confirming working mode and travel speed After the display of machine inspection before day's work, amplified symbol marks for working mode and travel speed are shown for 2 seconds to urge an operator to confirm the setting.
6. Function for display of ordinary items The display of confirming working mode and travel speed is switched to this display of ordinary items. a If the working mode setting or travel speed setting is changed, or auto-deceleration or windshield wiper setting is activated while this is in display, an amplified corresponding symbol mark is shown for 2 seconds. a In this display, a symbol mark for preheat monitor is shown only when preheating is carried out. 7. Function for adjusting display luminance and contrast Luminance as well as contrast of the display can be adjusted by operating the display adjusting switch.
8. Function for confirming maintenance information Detailed information on maintenance items (set time and elapse of time) can be confirmed and resetting after the confirmation is feasible by operating the maintenance switch. a Use Service Menu for setting or releasing maintenance items and setting maintenance time.
PC750, 800-7
20-161 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
9. Function for showing service meter reading Only the service meter reading can be shown by the following switching operation, when the engine starting switch is turned OFF. • Switching operation: [ ] + [ ] (synchronized switching operation)
10. Function for checking display LCD Display of the Display LCD can be confirmed by the following switching operation in the display of ordinary items • Switching operation: [ ] + [A] (synchronized switching operation) a All the LCD light up, turning the entire screen white. If there is no showing in black, the display is normal. a This display returns to the immediately preceding one, if making any other switching operation. 11. Function for showing occurrence of caution item If any of the caution items occurs, the magnified corresponding symbol mark is shown for 2 seconds and thereafter stays on the display as a small symbol mark until it is dissolved.
12. Function for showing users' code No. When a trouble occurs on the machine, the user's code is automatically displayed depending on the magnitude of the trouble to call attention of the operator for a proper action. a This display turns to the display of error code and failure code, if operating the switch (Refer to Item No. 13)
20-162 (1)
PC750, 800-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
a User codes and instructions given to operator User code
Failure mode
Instructions given to operator
Error in pump control system
If the emergency pump drive switch is set to the upper (emergency) position, the machine can operate normally. Have the machine inspected immediately, however.
E03
Error in swing brake system
Set the swing holding brake release switch to the upper (release) position to release the brake. When applying the swing brake, use the swing lock switch. The error may not be reset, depending on the cause of the failure. In any case, have the machine inspected immediately.
E10
Error in engine controller power supply system Abnormality in engine controller drive system circuit (engine stop)
Have the machine inspected immediately.
E11
Error in engine controller system (Engine protection output down)
Set the machine in a safe position and have the machine inspected immediately.
E14
Error is throttle system
Set the machine in a safe position and have the machine inspected immediately.
E15
Error in engine sensor (water temperature, fuel temperature and oil pressure)
Ordinary operation is possible. Have the machine inspected immediately, however.
E0E
Error in network
Set the machine in a safe position and have the machine inspected immediately.
E02
PC750, 800-7
20-163 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
13. Function for showing error code No. and failure code No. If the following switching operation is made while the users' code No. is shown, a phone symbol (if registered), phone numbers (if registered), error code No. and failure code No. are shown in turn. • Switching operation: [ ] a The following display is repeated in order according to the operation of the switch. [1] Telephone symbol mark [2] Telephone No. [3] Error code No. and failure code No. a The telephone symbol mark and telephone No. are shown only when they are registered in the monitor panel. For registration, correction and deletion of telephone No., use Service Menu. a For details on the displayed error code No. and failure code No., refer to the Table for Error and Failure Code Nos.
20-164 (1)
PC750, 800-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
Error code Code
Contents
Failure code Code
Component
History division
User code
Table for Error and Failure Code Nos.
Trouble
E112 Wiper Drive (For) S/C
DY2DKB Wiper motor (Forward)
Short circuit
—
E113 Wiper Drive (Rev) S/C
DY2EKB Wiper motor (Reverse)
Short circuit
—
E114 Washer Drive S/C
Windshield washer DY2CKB motor
Short circuit
—
E115 Wiper Working Abnormality
DY20KA Wiper motor
Disconnection
—
E116 Wiper Parking Abnormality
DY20MA Wiper motor
Malfunction
—
E117 Eng. Controller S-NET Comm Err.
DAC0KR Engine controller
Communication trouble (Abnormality in objective component system)
—
E118 Pump Controler S-NET Comm Err.
DAB0KR Pump controller
Communication trouble (Abnormality in objective component system)
E0E E128 Monitor Comm. Abnormality
DAFRMC
Monitor CAN communication
Defective operation
—
E201 CO Cancel Sol. S/C
DW48KB
Cut-off cancel solenoid valve
Short circuit
—
E202 Travel Junction Sol. S/C
DW91KB
Travel neutral solenoid valve
Short circuit
DW45KB
Swing holding brake solenoid valve
Short circuit
2-stage relief solenoid valve
Short circuit
E03 E203 Swing Brake Sol. S/C —
E204 2-stage Relief Sol. S/C
DWK0KB
—
E205 Swing Priority Sol. S/C
DW41KB Swing solenoid valve
—
E206 Travel Speed Sol. S/C
Travel high-low selector DW43KB Short circuit solenoid valve
—
E207 Flash Light Relay S/C
D163KB
Flash light drive relay
Short circuit
—
E211 CO Cancel Sol. Disc.
DW48KA
Cut-off cancel solenoid valve
Disconnection
—
E212 Travel Junction Sol. Disc.
DW91KA
Travel neutral solenoid valve
Disconnection
DW45KA
Swing holding brake solenoid valve
Disconnection
2-stage relief solenoid valve
Disconnection
E03 E213 Swing Brake Sol. Disc.
Electrical system
—
Short circuit
—
E214 2-stage Relief Sol. Disc.
DWK0KA
—
E215 Swing Priority Sol. Disc.
DW41KA Swing solenoid valve
—
E216 Travel Speed Sol. Disc.
Travel high-low selector DW43KA Disconnection solenoid valve
—
E217 Model selection Abnormality
DA2SKQ
Pump controller model Disagreement of model selection wiring harness selection signals
DA2SKA
Pump controller S-NET communication
E0E E218 S-Net Comm. Disc.
Disconnection
Disconnection
—
E221 Travel Alarm S/C
DV20KB Backup alarm buzzer
Short circuit
—
E224 F Pump P. Sensor Abnormality
DHPAMA
Front pump pressure sensor
Malfunction
—
E225 R Pump P. Sensor Abnormality
DHPBMA
Rear pump pressure sensor
Malfunction
—
E226 Press. Sensor Power Abnormality
DA25KP
Output of pump control- Lowering of output ler power supply voltage
PC750, 800-7
20-165 (1)
—
Error code Code
Contents
Code
Component
Trouble
DLE2MA Engine speed sensor
Malfunction
E02 E232 TVC Sol. S/C
DXA0KB TVC solenoid valve
Short circuit
E02 E233 TVC Sol. Disc.
DXA0KA TVC solenoid valve
Disconnection
E0E E257 Pump Comm. Abnormality
Pump controller CAN DA2RMC communication
Defective operation
D195KB
Step light drive relay
Short circuit Short circuit
—
E227 Engine Speed Sensor Abnormality
Failure code
E302 Step Light Relay S/C
—
E304 Step Light Power Hold Relay S/C
D194KB
Step light power source holding relay
—
E315 Battery Relay Drive S/C
D110KB
Battery relay
Short circuit
E11 E91B Engine Ne sensor problem
DLE3LC
Ne speed sensor
Disagreement of speed signals
E11 E91C Engine G sensor problem
DLH1LC G speed sensor
E11 E920 Engine type selection error
DB29KQ
E11 E921 Engine type mismatch
DB20KQ Engine controller
Disagreement of model selection signals
E14 E931 Fuel dial sys. error
DK10KX Throttle angle sensor
Out of input signal range
E15 E934 Engine coolant sensor Hi error
Engine water temperaDGE2KX ture sensor
Out of input signal range
E15 E936 Engine oil press. sw. error
DDE2L6
Disagreement of speed signals
Engine controller model Disagreement of model selection wiring harness selection signals
Engine oil pressure switch
Disagreement of signals and run/stop of engine
E11 E93C Engine boost sensor error
DH30KX Boost pressure sensor
E15 E93D Engine fuel temp. sensor error
DGE4KX Fuel temperature sensor Out of input signal range
E0E E953 Engine Comm. Abnormality
DB2RMC
—
E954 Short engine starter sw.
Engine controller CAN communication
DD11KB Starting switch
Out of input signal range
Defective operation Short circuit
E0E E955 Engine S-NET error
DB2SMC
Engine controller S-NET Defective operation communication
E10 E956 Engine power failure (1)
DB22KK
Engine controller load power source line
Lowering of source voltage (Input)
E15 E957 Engine power failure (2)
D1D0KB
Engine controller load power source relay
Short circuit
DB2AMA
Rotary switch in engine controller
Malfunction
E15 E96A Engine coolant sensor Lo error
DGE3L6
Engine water temperature sensor 2
Disagreement of signals and run/stop of engine
E11 E970 PCV1 over current
AD11KB
Supply pump (1) solenoid valve
Short circuit
E11 E971 PCV2 over current
AD51KB
Supply pump (2) solenoid valve
Short circuit
E11 E974 PCV1 line cut
AD11KA
Supply pump (1) solenoid valve
Disconnection
E11 E975 PCV2 line cut
AD51KA
Supply pump (2) solenoid valve
Disconnection
E11 E977 Rail press. sensor error
DH40KX
Common rail fuel pressure sensor
Out of input signal range
E11 E979 Rail press. high
AD00L2
Common rail
Fuel pressure is too high
—
E95A Engine Q-adj. sw. signal error
20-166 (1)
History division
SPECIAL FUNCTION OF MONITOR PANEL
Electrical system
User code
TESTING AND ADJUSTING
PC750, 800-7
SPECIAL FUNCTION OF MONITOR PANEL
Code
Contents
Failure code Code
Component
History division
Error code
Trouble
AD00MA Common rail
Malfunction
AD10L3
Uncontrollability
E11 E97C Rail press. too low
AD10MB Supply pump
Lowering of function
E11 E97D Rail press.out of control
AD10MA Supply pump
Malfunction
E10 or E980 Eng. Controller Abnormality E11
DB20KT
Abnormality in controller
E11 E981 Fuel Injector 1 Disc.
ADA1KA Injector 1 solenoid valve Disconnection
E11 E982 Fuel Injector 2 Disc.
ADB1KA Injector 2 solenoid valve Disconnection
E11 E983 Fuel Injector 3 Disc.
ADC1KA Injector 3 solenoid valve Disconnection
E11 E984 Fuel Injector 4 Disc.
ADD1KA Injector 4 solenoid valve Disconnection
E11 E985 Fuel Injector 5 Disc.
ADE1KA Injector 5 solenoid valve Disconnection
E11 E986 Fuel Injector 6 Disc.
ADF1KA Injector 6 solenoid valve Disconnection
E11 E98A Fuel Injector 1 – 3 S/C
ADAZKB
Injector 1, 2, 3 solenoid valve
Short circuit
E11 E98B Fuel Injector 4 – 6 S/C
ADDZKB
Injector 4, 5, 6 solenoid valve
Short circuit
A000KX
Engine
Out of input signal range
Engine
Overrun
Supply pump
Engine controller
—
None Eng. Lo Out of Std
—
None Eng. Hi Out of Std
A000N1
—
None Aircleaner Clogging
AA10NX Air cleaner element
—
None Charge Voltage Low
E11 E924 Eng. Oil Press. Low
AB00KE
Alternator
B@BAZG Engine oil
Electrical system
E11 E97A Rail press. abnormal E15 E97B Rail press. low
Clogging Defective charge Lowering of oil pressure
—
None Eng. Oil Level Low
B@BAZK Engine oil
Lowering of level
—
None Eng. Water Overheat
B@BCNS Cooling water
Overheating
—
None Eng. Water Lvl Low
B@BCZK Cooling water
Lowering of level
—
None Hydr. Oil Overheat
B@HANS Hydraulic oil
Overheating
—
None Auto. Lub. Abnormal.
DA80MA Auto grease controller
Malfunction
Mechanical system
User code
TESTING AND ADJUSTING
a The items in this list are arranged in the order of the error codes. a The error codes having no numbers in the user code column and the failure codes having no numbers in the user code column and error code column are not displayed on the normal screen, even if abnormality related to them occurs. They are simply recorded in the failure history of the service menu (Electrical system or mechanical system). a The history division column shows in which division each failure is classified, the electrical system or mechanical system, when it is recorded in the failure history. a In "Error code: E924/Failure code: B@BAZG", the error code is displayed only when the user code is turned ON and the failure code is recorded in only the mechanical system of the failure history. a Letter "E" at the head of each error code indicates the following condition. • With E: The failure has not been repaired yet. • Without E: The failure has been repaired.
PC750, 800-7
20-167 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
Operation and Display of Service Menu Way of switching to Service Menu a When using Service Menu, change the display to Service Menu display through the following special operation. 1) Confirmation of display Confirm that the display of ordinary items is shown. a Changing to Service Menu cannot be made from displays other than this.
2) Switch operation Operate the switch as instructed below. • Switch operation: [ ] + [1] o [2] o [3] (Enter a figure, depressing [
])
3) Showing Service Menu display The display is changed to the initial display of Service Menu program. Select an appropriate item from among the menu. No.
Service Menu
00
Return (Termination of Service Menu)
01
Monitoring
02
Abnormality Record
03
Maintenance Record
04
Maintenance Mode Change
05
Phone Number Entry
06
AAAAA / Default
07
Adjustment
08
Cylinder cut out
4) Termination of Service Menu function When terminating the initial display or any subsequent display of Service Menu, do that through any one of the following methods. [1] Depress [ ] switch. (This method may be used for terminating any display) [2] If "Return" switch is shown, depress it. [3] If "Return" menu is shown, call that menu and depress [ ] switch.
20-168 (2)
PC750, 800-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
14. Function of Monitoring [01] The monitor panel monitors signals from an assortment of switches, sensors and actuators installed in various parts of the machine. Monitored information can be put in display or confirmed on a real time basis through the following operations. 1) Selection of menu Select "01 Monitoring" in the initial display of Service Menu and depress [ ] switch. 2) Setting of monitoring item Select or register an item to be monitored through the following switch operation. • [ ] switch: Selection • [ ] switch: Selection • [ ] switch: Registration a A monitoring item can be set in any number between the min. one to the max. four. (Depending upon the selected item, the max. number is less than four) a In case of monitoring 1 to 3 items, move to the monitored information display through any of the following switch operations, after the registration work has been completed. • Keep [ ] switch depressed. (For about 3 seconds) • Select Menu 99999 and depress [ ] switch. a The display automatically moves to the display of monitored information, when all of the registrable items have been duly registered. a Monitored information are transmitted via communication circuits. Thus the number of selected items can impact the communication speed. If truly real time monitoring is required, reduce the selected items to the minimum. a For details on the monitoring items, display unit, etc., refer to the Table for Monitoring Items.
PC750, 800-7
20-169 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
3) Monitoring operation Call the monitoring information display and confirm the monitored information, while operating the machine.
4) Monitored information holding function If [ ] switch is depressed while monitoring, all the monitored information are put on hold. If [ ] switch is depressed in this condition, information holding is released.
5) Machine setting mode switching function If it becomes necessary to change settings of working mode, travel speed and autodecel while monitoring, depress the corresponding switch, then the mode confirmation display is shown. a When a specific setting is confirmed, depress [ ] switch, then the display returns to that of monitoring. a In case a specific setting has been changed while monitoring, the new setting is still maintained when returning from Service Menu to Operator's Menu after the monitoring is finished.
20-170 (1)
PC750, 800-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
Monitoring items list Code No.
Monitoring item
Unit (Default: SI) SI
meter
inch
Remarks
00000 Return
(Not displayed)
Finish menu
99999 Display and execution
(Not displayed)
Display and execution menu
00200 Controller Model Select
Numeral
00201 Controller Model Select
Numeral
01002 Engine Speed
r/min
rpm
rpm
01601 2nd Eng. Speed Command
r/min
rpm
rpm
01100 F Pump Pressure
MPa
kg/cm2
psi
01101 R Pump Pressure
MPa
kg/cm
psi
04102 Engine Water Temp. Hi
°C
°C
°F
14200 Fuel Temperature
°C
°C
°F
04401 Hydr. Oil Temperature
°C
°C
°F
01300 TVC Sol. Curr.
mA
mA
mA
03200 Battery Voltage
V
V
V
03500 Battery Relay O/P Vol.
V
V
V
04300 Battery Charge Vol.
V
V
V
r/min
rpm
rpm
°C
°C
°F
36400 Rail Pressure
MPa
kg/cm2
psi
36500 Boost Pressure
kPa
kg/cm2
psi
36700 Torque Ratio
%
%
%
03000 Fuel Dial Vol.
V
V
V
04200 Fuel Level Sensor Vol.
V
V
V
04106 Eng. Water Temp. Vol. Hi
V
V
V
04105 Eng. Water Temp. Vol. Lo
V
V
V
14201 Fuel Temp. Sensor Vol.
V
V
V
36501 Boost Press. Sensor Vol.
V
V
V
36401 Rail Press. Sensor Vol.
V
V
V
CA
CA
CA
01006 Engine Speed 04107 Engine Water Temp. Low
17200 PCV Close Angle 17300 Eng. Controll Mode 31701 Throttle Level
2
Numeral %
%
%
36100 Fuel Delivery Command
mm3/st
mm3/st
mm3/st
36200 Rail Pressure Command
MPa
kg/cm2
psi
36300 Injection Timing Angle
CA
CA
CA
37300 Fuel Consumption Rate
L/h
L/h
L/h
L
L
L
14300 Fuel Consumption
PC750, 800-7
20-171 (1)
TESTING AND ADJUSTING
Code No.
SPECIAL FUNCTION OF MONITOR PANEL
Unit (Default: SI)
Monitoring item
01900 Pressur Switch 1
01901 Pressur Switch 2
02300 Solenoid Valve 1
02200 Switch Input 1
02201 Switch Input 2
SI
Swing
ON/OFF
R.H Travel
ON/OFF
Boom Lower
ON/OFF
Boom Raise
ON/OFF
Arm Curl
ON/OFF
Arm Dump
ON/OFF
Bucket Curl
ON/OFF
Bucket Dump
ON/OFF
Service
ON/OFF
L.H Travel
ON/OFF
Travel Junction
ON/OFF
Swing Brake
ON/OFF
2-Stage Relief
ON/OFF
Travel Speed
ON/OFF
CO Cancel
ON/OFF
Swing Priority
ON/OFF
Lever Sw.
ON/OFF
Swing Release Sw
ON/OFF
Swing Brake Sw.
ON/OFF
Model Select 1
ON/OFF
Model Select 2
ON/OFF
Model Select 3
ON/OFF
Model Select 4
ON/OFF
Model Select 5
ON/OFF
— 02202 Switch Input 3
meter
ON/OFF
Step Light Sw.
ON/OFF
Horn Sw.
ON/OFF
Over Load Sensor
ON/OFF
Auto Greacing
ON/OFF
03700 Controller Output 1 Batt. Relay Dr.
ON/OFF
05500 Sensor Input 1
03701 Controller Output 2
20-172 (1)
Remarks
ON/OFF
Key Switch (ACC)
02203 Switch Input 4
inch
Step L.Pwr.Relay
ON/OFF
Step L. Relay
ON/OFF
Flash L. Relay
ON/OFF
Travel Alarm
ON/OFF
PC750, 800-7
TESTING AND ADJUSTING
Code No.
Monitoring item
04500 Monitor Input 1
04501 Monitor Input 2
04502 Monitor Input 3
17400
Eng. Controller Input
SPECIAL FUNCTION OF MONITOR PANEL
Unit (Default: SI) SI
meter
Key Switch
ON/OFF
Start
ON/OFF
Preheat
ON/OFF
Light
ON/OFF
Rad. Level
ON/OFF
Aircleaner
ON/OFF
Eng. Oil Level
ON/OFF
Battery Charge
ON/OFF
Swing Brake Sw.
ON/OFF
Bzzr Cancel Sw.
ON/OFF
Window Limit Sw.
ON/OFF
W Limit Sw.
ON/OFF
Upper P Limit Sw./P Limit Sw.
ON/OFF
Lower P Limit Sw./—
ON/OFF
Key SW(C)
ON/OFF
Eng. Oil Press. Lo
ON/OFF
Eng. Oil Press. Hi
ON/OFF
Machine Sel. 1
ON/OFF
Machine Sel. 2
ON/OFF
Machine Sel. 3
ON/OFF
inch
36800 Q Adjust Switch R
Numeral and alphabet
36801 Q Adjust Switch L
Numeral and alphabet
05100 S-NET Connection
Pump Controller
ON/OFF
Engine Controller
ON/OFF
20200 Monitor Prog. Version
Numeral
20212 Pump Con. Prog. Version
Numeral
20209 Eng. Con. Prog. Version
Numeral
Remarks
Display is a little different between double-wiper specification and single-wiper specification.
a As the unit of display, one of "SI unit system", "Metric unit system", and "Inch unit system" can be selected. a The unit of display can be changed with "Selection of unit" in the "AAAA/ Default" function of the service menu. a "CA" of the unit of display denotes the crankshaft angle. Note 1: The momentary fuel consumption ratio shown above is the theoretical fuel consumption ratio (Since it is a theoretical value, it is a little different from the actual fuel consumption ratio). Note 2: The fuel consumption amount is the theoretical fuel consumption amount after the engine is started until the engine is stopped (Since it is a theoretical value, it is a little different from the actual fuel consumption amount).
PC750, 800-7
20-173 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
15. Function for Abnormality Record [02] The monitor panel records failures that occurred on the machines in the past after classifying them into failures in the electric system and those in the mechanical system. Information on them can be displayed through the following operation. 1) Selection of menu Select 02 Abnormality Record in the initial display of Service Menu and depress [ ] switch.
2) Selection of Submenu Select an appropriate item from Submenu in the Abnormality Record display and depress [ ] switch. No.
Abnormality Record Submenu
00
Return (termination of Abnormality Record)
01
Electrical Systems
02
Mechanical Systems
3) Information shown in display of Abnormality Record in the electrical system [1]: The numerator expresses sequence of failure occurrence, counting from the latest one. The denominator expresses the total number of a specific failure recorded. [2]: Error Code [3]: Abnormality Code No. (section in 4 digits and phenomenon in 2 digits) [4]: Time elapsed since the occurrence of the first failure [5]: Contents of failure a Refer to "Table for Error Code and Abnormality Code" in Operator's Menu. 4) Information shown in display of Failure History in the mechanical systems [1]: Record No. [2]: Contents of Abnormality [3]: Abnormality Code No. (section in 4 digits and phenomenon in 2 digits) [4]: Total number of occurrence [5]: Service meter reading at the initial occurrence a Refer to "Table for Error Code and Abnormality Code" in Operator's Menu.
20-174 (1)
PC750, 800-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
5) Resetting Electrical Systems a Resetting Electrical Systems (deletion) is possible only with the electrical system. The failure history in the mechanical system cannot be reset. a For resetting any specific or all information in the Electrical Systems, follow the operation explained below. i) Through the following switch operation, call the resetting display in the display of Electrical Systems. • Switch operation: [ ] +[1] o [2] o [3] a This is the same switch operation in changing the display to Service Menu. ii) Operate the switch, following the instructions shown in the resetting display. a When resetting specific information only, call the display of that specific information and reset it with either [ ] switch or [ ] switch. a When resetting all the information, a display of any information will do.
PC750, 800-7
20-175 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
16. Function for Maintenance Record [03] The monitor panel records information on the maintenance of filters and oils. The stored information can be displayed through the following switch operation. 1) Selection of menu Select 03 Maintenance Record in Service Menu and depress [ ] switch.
2) Information to be displayed [1]: Name of oils and filters [2]: Times of replacement to date [3]: Service meter reading at the latest replacement
20-176 (1)
PC750, 800-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
17. Function for Maintenance Mode Change [04] Conditions set for controlling maintenance display function can be changed in the following manner. • Turn the function effectual or ineffectual. • Change the set interval for replacement. 1) Selection of menu Select 04 Maintenance Mode Change in the initial display of Service Menu, and depress [ ] switch.
2) Selection of item to be changed Select an item to be changed in the display of Maintenance Mode Change Selecting Menu. No.
Maintenance mode change item
00
Return (Termination of maintenance mode change)
01
Maintenance Mode On/Off
02
Engine Oil Exch. Int.
03
Engine Oil Filter Exch. Int.
04
Fuel Filter Exch. Int.
05
Hydr. Oil Filter Exch. Int.
06
H/Tank Breather Exch. Int.
07
Corro. Resis. Exch. Int.
08
PTO Oil Service Int.
09
Final Drive Oil Exch. Int.
10
S/Machinery Oil Exch. Int.
11
Hydraulic Oil Exch. Int.
12
Pilot Filter Exch. Int.
13
Drain Filter Exch. Int.
14
Use Default Values
a 01 and 14 menus are provided for setting the whole maintenance mode, while those from 02 through 13 are for setting individual items. 3) Contents of Maintenance Mode On/Off • Use: The maintenance display function of all oil and filter-related items are turned effectual. (Irrespective of whether "On" or "Off" set for individual items, this setting prevails) • Do not use: The maintenance display function of all oil and filter-related items are turned ineffectual. (Irrespective of whether "On" or "Off" set for individual items, this setting prevails) PC750, 800-7
20-177 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
4) Set contents of individual items [1]: Default: The maintenance time set in the monitor (recommended by the manufacturer and cannot be changed). [2]: Set: Maintenance time that can be freely set. The maintenance mode program functions based on this maintenance time. (The maintenance time can be increased or decreased by 50 hours with [ ] or [ ] switch) [3]: On: Maintenance display function with this instruction becomes effectual. [4]: Off: Maintenance display with this instruction becomes ineffectual. a The lowest maintenance time is 50 h. 5) Set contents of "Use Default Values" When selecting this menu and depressing the switch [ ], all individual time settings are reduced to the initial settings.
20-178 (1)
PC750, 800-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
18. Function for Phone Number Entry [05] In the display of User Code, a telephone number and Service Code are shown alternately. Phone number can be inputted or modified in the following manner. a If there is no Phone number registered, the display for Phone numbers does not appear. 1) Selection of menu Select 05 Phone Number Entry menu in the display of Service Menu, and depress [ ] switch. 2) Changing the display Select Entry next to change the display to the Phone Number Entry display. a Even if a Phone number is already inputted, it is deleted, upon switching to the Phone Number Entry display.
3) Entry and setting Phone number Following the method explained below, Entry a Phone number in the Phone Number Entry display. (Entry automatically begins with a cursor at the left end) i) Enter a number into a cursor at the left end with a ten-key. ii) Depress [ ] switch when all the numbers have been entered. a Numbers can be entered up to the max. 12 digits, but omit unnecessary digits. a When entering a wrong number, depress [Swing priority] switch, then the cursor goes back by one digit. a When input is finished, the display changes to Entry display shown above. If the inputted Phone number is shown in this display, the input is normal.
PC750, 800-7
20-179 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
19. Function for AAAA/Default [06] AAAA It is possible to change the following settings for the monitor panel as well as the machine. Make a change as is required. • Working mode when the engine starting switch is in the ON position. • Display language in Service Menu • Display unit in the monitoring function • Setting of double wiper or single wiper 1) Selection of menu Select 06 "AAAA/Default menu" in the initial display of Service Menu, and depress [ ] switch. 2) Selection of submenu Select an item to change from the submenu, and depress [ ] switch. AAAA/Default submenu
No. 00
Return (termination of AAAA/Default)
01
Key-on Mode
02
AA/Language
03
Unit
04
Wiper Select
3) Function for Key-on Mode When the engine starting switch is turned ON, a working mode can be set that is shown in the monitor panel. • A Mode, E Mode, Heavy Lift Mode OFF/ ON, Swing Priority Mode OFF/ON: If any of them is set, the machine always ramps up with that working mode, when turning the engine starting switch ON. • Mode at Previous Key-off: If this mode is set, the machine ramps up with the working mode that was last used in the previous machine operation. • Default Value: If this mode is set, the machine ramps up with the default mode (A mode) that was originally set at the time of delivery from the factory.
20-180 (1)
PC750, 800-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
4) Function for AA/Language In Service Menu, the language in use can be changed between Japanese and English. a English is used as the language for default setting in the monitor panel. a If the monitor panel for spare parts is to be used in a Japanese-speaking region or organization, change the language from English to Japanese, using this function.
5) Function for unit selection As the unit to be used in the monitoring function display of Service Menu, three kinds of unit are provided. a Unit used for default setting in the monitor panel is SI, i.e. International System of Units.
6) Function for selection of wiper specification The wiper specification can be set. • 1 wiper: Machine with standard cab or fixed-front window cab (Only upper wiper) • 2 wipers: Machine with fixed-front window cab (if equipped) (Upper wiper and lower wiper) a If this setting is not matched to the specification of the actually installed wiper, the wiper may not operate normally or an error is detected.
PC750, 800-7
20-181 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
20. Function of adjustment [07] The machine can be adjusted with the monitor panel. 1) Selection of menu Select "07 Adjustment" on the service menu and press the [ ] switch. 2) Selection of sub menu Select the sub menu to check the setting and press the [ ] switch. No.
Sub menu of adjustment
00
Return (Finish adjustment)
01
Pump Absorption Torque
3) Function of pump absorption torque The pump absorption torque can be adjusted in the following ranges. a Basically, this setting does not need to be changed. Adjustment value 220
+98.1 Nm {+10.0 kgm}
221
+73.5 Nm {+7.5 kgm}
222
+49.0 Nm {+5.0 kgm}
223
+24.5 Nm {+2.5 kgm}
224
20-182 (1)
Sub menu of adjustment
0.0 Nm {0.0 kgm}
225
–24.5 Nm {–2.5 kgm}
226
–49.0 Nm {–5.0 kgm}
227
–73.5 Nm {–7.5 kgm}
228
–98.1 Nm {–10.0 kgm}
PC750, 800-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
21. Function of reduced cylinder mode operation [08] The reduced cylinder mode can be controlled with the monitor panel. Reduced cylinder mode operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal).
1) Selection of menu Select "08 Cylinder cut out" on the initial screen of the service menu and press the [ ] switch.
2) Setting of cylinders to be disabled Press switches [1] – [6] on the monitor panel corresponding to the cylinder Nos. to be disabled. a After a switch is pressed, if the cylinder No. corresponding to it on the monitor panel is displayed white in a white frame, the cylinder is disabled (If setting is wrong, press the same switch again). a Only one or more cylinders can be disabled for the reduced cylinder mode operation. 3) Cancellation of disabled cylinders Press switches [1] – [6] on the monitor panel corresponding to the disabled cylinder Nos. to cancel disabling of those cylinders. a After a switch is pressed, if the cylinder No. corresponding to it on the monitor panel is displayed black in a black frame, disabling of the cylinder is cancelled.
PC750, 800-7
20-183 (2)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MONITOR PANEL
4) Function of holding engine speed If the [ ] switch is pressed while the reduced cylinder mode operation screen is used, the engine speed is held and displayed on the lower line. If the [ ] switch is pressed while the engine speed is held, holding of the engine speed is cancelled and the engine speed displayed on the lower line goes off. a If the holding function is used, the held engine speed is displayed in ( ) on the lower line and the current engine speed is displayed on the upper line. a The holding function can be used both in and out of the reduced cylinder mode.
[Reference]: How to use holding function effectively The engine speed displayed by the holding function is held on the screen until the holding function is cancelled, regardless of setting and cancellation of the reduced cylinder mode. Accordingly, a defective cylinder can be found out effectively according to the following procedure. (1) Run the engine normally (without disabling any cylinder) and hold the engine speed. (2) Disable a cylinder to be checked. (3) Run the engine under the same condition as the normal operation in step (1) and compare the engine speed at this time with the held engine speed. (4) If there is not a difference between the current engine speed and the held engine speed in step (3), cancel the reduced cylinder mode. (5) Repeat steps (2) - (4) to check the other cylinders.
20-184 (1)
PC750, 800-7
TESTING AND ADJUSTING
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT
k The engine controller is equipped with high voltage circuits (110-130 V) for driving the fuel injector. They are connected to the connectors and harnesses between the engine controller and the fuel injector. a Normally, a high voltage is only output while the engine is running. Once the engine is stopped, the output ceases. k Touching the high voltage circuit directly may cause an electric shock. To avoid this, observe the following precautions when inspecting the circuits. 1. Connectors containing high voltage circuits: • Engine controller connector: E13 • Relay connector: A13, A14 • Injector connector: CN1, CN2, CN3, CN4, CN5, CN6 • Injector head terminal (in head cover) 2. Be sure to connect and disconnect the relevant connectors with the starting switch off. 3. When diagnosing, do not start the engine with the T-adapter inserted in or connected to the relevant connector. a At that time, the starting switch can be set to ON and OFF only, but not to START.
PC750, 800-7
20-185 (1)
TESTING AND ADJUSTING
PREPARATION WORK
PREPARATION WORK a When troubleshooting an electric circuit related to the monitor panel, engine controller, or pump controller, expose the related connectors according to the following procedure. 1. Monitor panel 1) Remove cover (1). a The cover is secured with 2 clips at the top and bottom. Those clips can be removed by pulling them up. a If a sunlight sensor for the air conditioner is installed, disconnect connector P15 on the backside of the cover.
2) Remove the 3 mounting screws and disconnect monitor panel (2) from the mount. a Take care not to drop the mounting screws in the console. 3) Insert or connect T-adapters for troubleshooting to connectors P01, P02, and P70 of the monitor panel.
20-186 (1)
2. Engine controller 1) Slide the operator's seat and seat stand forward to the stroke end. 2) Insert or connect T-adapters for troubleshooting to connectors E11, E12, and E13 of engine controller (3). a Since the connectors are secured with screws, loosen those screws before disconnecting them. a After returning the connectors, tighten the screws to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm}
3. Pump controller a The pump controller is installed in the cover at the rear of the operator's seat. 1) Remove 3 caps (4) and 3 mounting bolts. a Remove the caps with a thin flat-head screwdriver. 2) Remove cover (5).
PC750, 800-7
TESTING AND ADJUSTING
PREPARATION WORK
3) Insert or connect T-adapters for troubleshooting to connectors C01, C02, and C03 of the pump controller (6). a Since the connectors are secured with screws, loosen those screws before disconnecting them. a After returning the connectors, tighten the screws to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm}
PC750, 800-7
20-187 (1)
PM-CLINIC SERVICE
Specification of machine
PC750, 800-7
20-189 (1)
MEASURING PROCEDURES
Positions to install measuring devices (Related to engine and PTO)
20-190 (1)
PC750, 800-7
MEASURING PROCEDURES
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)
PC750, 800-7
20-191 (1)
20-192 (1)
PC750, 800-7
PC750, 800-7
20-193 (1)
Pm-CLINIC SERVICE PC750 (LC, SE), 800 (SE)-7 Visual check of welded structures (For PC750, 750LC, 800-7) a If any crack is found, draw its shape below.
Arm 1. Arm cylinder bracket T Left T Right 2. Arm foot T Left T Right T End plate 3. Arm top boss T Left T Right
20-194 (1)
Boom 4. Boom top bracket T Left T Right 5. Boom cylinder bracket T Left T Right 6. Arm cylinder bracket T Left T Right 7. Boom lower plate T Left T Right 8. Boom foot T Left T Right
Revolving frame 9. Boom bracket T Left T Right Track frame 10. Circle bracket T Front T Rear T Left T Right 11. Track frame mounting section T Front T Rear T Left T Right
PC750, 800-7
Visual check of welded structures (For PC750SE, 800SE-7) a If any crack is found, draw its shape below.
Arm 1. Arm cylinder bracket T Left T Right 2. Arm foot T Left T Right T End plate 3. Arm top boss T Left T Right
PC750, 800-7
Boom 4. Boom top bracket T Left T Right 5. Boom cylinder bracket T Left T Right 6. Arm cylinder bracket T Left T Right 7. Boom lower plate T Left T Right 8. Boom foot T Left T Right
Revolving frame 9. Boom bracket T Left T Right Track frame 10. Circle bracket T Front T Rear T Left T Right 11. Track frame mounting section T Front T Rear T Left T Right
20-195 (1)
TESTING AND ADJUSTING
UNDERCARRIAGE INSPECTION
20-196 (1)
UNDERCARRIAGE INSPECTION
(Program form No.: ***************)
PC750, 800-7
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204 CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213 CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...................... 20-217 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-234 T-BRANCH BOX AND T-BRANCH TABLE................................................................................................. 20-256 TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE DISPLAYED........................................................... 20-301 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) ................................................................. 20-501 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) ................................. 20-601 TROUBLESHOOTING OF ENGINE (S MODE).......................................................................................... 20-701
PC750, 800-7
20-201 (1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers. 4) Check the stroke of the control valve spool.
20-202 (1)
5) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure • Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting • Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure • Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
PC750, 800-7
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC750, 800-7
20-203 (1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic equipment" (particularly gear oil and hydraulic oil). 1. Points to remember when handling electric equipment 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
20-204 (1)
PC750, 800-7
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
PC750, 800-7
20-205 (1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
2) Removing, installing, and drying connectors and wiring harnesses •
Disconnecting connectors 1) Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2) When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. a If the connector is twisted up and down or to the left or right, the housing may break.
3) Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
20-206 (1)
PC750, 800-7
TROUBLESHOOTING
•
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Connecting connectors 1) Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2) Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. 3) Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. 4) If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
•
Connecting connectors (DT type connector) Since the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them in until they click 2 times. 1. Male connector, 2. Female connector • Normal locking state (Horizontal): a, b, d • Incomplete locking state (Diagonal): c
PC750, 800-7
20-207 (1)
TROUBLESHOOTING
•
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1) Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. 2) Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
3) Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the connector, blow it with contact restorer and reassemble.
20-208 (1)
PC750, 800-7
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Handling control box 1) The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. 2) Do not open the cover of the control box unless necessary.
3) Do not place objects on top of the control box. 4) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 5) During rainy weather, do not leave the control box in a place where it is exposed to rain.
6) Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 7) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
PC750, 800-7
20-209 (1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3. Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment. 3) Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.
4) Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
20-210 (1)
PC750, 800-7
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6) Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7) Cleaning operations After repairing the hydraulic equipment (pump, c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
PC750, 800-7
20-211 (1)
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Electrics, electrical equipment
Hydraulic, Electrical mechanical equipment equipment
Lubricating oil, coolant
Item
20-212 (1)
Check fuel level, type of fuel Check for impurities in fuel Check hydraulic oil level Check hydraulic oil strainer Check swing machinery oil level Check engine oil level (oil pan oil level) Check coolant level Check dust indicator for clogging Check hydraulic filter Check final drive oil level
Judgement value — — — — — — — — — —
Action Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water Clean or replace Replace Add oil
1. Check for looseness, corrosion of battery terminal, wiring 2. Check for looseness, corrosion of alternator terminal, wiring 3. Check for looseness, corrosion of starting motor terminal, wiring
— — —
Tighten or replace Tighten or replace Tighten or replace
1. Check for abnormal noise, smell 2. Check for oil leakage 3. Carry out air bleeding
— — —
Repair Repair Bleed air
1. 2. 3. 4. 5.
Check battery voltage (engine stopped) Check battery electrolyte level Check for discolored, burnt, exposed wiring Check for missing wiring clamps, hanging wiring Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals) 6. Check for blown, corroded fuses 7. Check alternator voltage (engine running at 1/2 throttle or above)
8. Check operating sound of battery relay (when switch is turned ON/OFF)
20 – 30V — — — —
Replace Add or replace Replace Repair Disconnect connector and dry Replace Replace
— After running for several minutes : 27.5 – 29.5V — Replace
PC750, 800-7
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING Classification of troubleshooting Mode Code display
Content Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are displayed.
E mode
Troubleshooting of electrical system
H mode
Troubleshooting of hydraulic and mechanical systems
S mode
Troubleshooting of engine
Steps for troubleshooting If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting No. and proceed to the explanations for diagnosis. 1. Troubleshooting steps when calling User Code display in the monitor panel In the User Code display, select and depress [ ] switch to display Error Code. Following displayed Error Code for the electrical system, carry out the troubleshooting along the corresponding code display. 2. Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is recorded in the failure history: If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system Failure Code, using the failure history function of the monitor panel. a If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the display again to check if the same abnormality still persists. a Failure Code in the mechanical system cannot be deleted. 3. Troubleshooting steps without User Code display and no failure history is available If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechanical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from among "Failure like Phenomena and Troubleshooting No." and carry out E mode or H mode troubleshooting related to the phenomenon in question.
PC750, 800-7
20-213 (1)
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Failure-looking Phenomenon and Troubleshooting No. Troubleshooting No.
Failure-looking phenomenon
Code display
E mode
H mode
S mode
Action to be taken concerning Error Code, User Code and Failure Code 1
Display User Code in monitor panel
2
Display Error Code in electrical system after checking failure history
3
According to displayed Display Failure Code in mechanical system after checking failure hiscode tory Engine-related failure
4
Starting performance is poor (starting always takes time)
5 6
Engine does not turn Engine does not start
7
S-1 E-1
S-2 a)
Engine turns but no exhaust smoke comes out
S-2 b)
Exhaust smoke comes out but engine does not start (Fuel is being injected)
S-2 c)
8
Engine does not pick up smoothly (follow-up is poor)
S-3
9
Engine stops during operations
S-4
10
Engine does not rotate smoothly (hunting)
S-5
11
Engine lacks output (or lacks power)
S-6
12
Exhaust smoke is black (incomplete combustion)
S-7
13
Oil consumption is excessive (or exhaust smoke is blue)
S-8
14
Oil becomes contaminated quickly
S-9
15
Fuel consumption is excessive
S-10
16
Oil is in cooling water (or water spurts back, or water level goes down)
S-11
17
Oil pressure caution lamp lights up (drop in oil pressure)
S-12
18
Oil level rises (water, fuel in oil)
S-13
19
Water temperature becomes too high (overheating)
S-14
20
Abnormal noise is made
S-15
21
Vibration is excessive
S-16
22
Preheater does not operate
E-2
23
Auto engine warm-up device does not work
E-3
24
Auto-decelerator does not operate
E-4
Failure related to work equipment, swing and travel 25
Speed or power of all work equipment, travel, and swing is low
H-1
26
Engine speed lowers remarkably or engine stalls
H-2
27
All work equipment, travel, and swing systems do not work
28
Abnormal sound is heard from around pump
E-5
H-3 H-4
Work equipment-related failure 29
Boom speed or power is low
H-5
30
Speed or power of arm is low
H-6
31
Speed or power of bucket is low
H-7
20-214 (1)
PC750, 800-7
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting No.
Failure-looking phenomenon
Code display
E mode
H mode
32
Boom does not move
H-8
33
Arm does not move
H-9
34
Bucket does not move
H-10
35
Hydraulic drift of work equipment is large
H-11
36
Time lag of work equipment is large
H-12
37
Heavy lift function does not operate or stop
H-13
38
Machine push-up function does not operate or stop
E-6
H-14
39
Boom shockless function cannot be turned ON or OFF
E-7
H-15
S mode
Travel-related failure 40
Machine deviates in one direction
H-16
41
Machine deviates largely at start
H-17
42
Machine deviates largely during compound operation
H-18
43
Travel speed or power is low
H-19
44
Machine does not travel (only one track)
H-20
45
Travel speed does not change
H-21
46
Travel alarm does not sound or does not stop sounding
E-32
Swing-related falure 47
Upper structure does not swing
H-22
48
Swing speed or acceleration is low
H-23
49
Swing speed or acceleration is low during compound operation of swing and work equipment
H-24
50
Upper structure overruns excessively when it stops swinging
H-25
51
Large shock is made when upper structure stops swinging
H-26
52
Large abnormal sound is made when upper structure stops swinging
H-27
53
Hydraulic drift of swing is large
H-28
Monitor panel-related failure (Operator’s Menu: ordinary Display) 54
Any item is not displayed on monitor panel
E-8
55
Part of display on monitor panel is missing
E-9
56
Monitor panel displays contents irrelevant to the model
E-10
57
Fuel level monitor red lamp lights up while engine is running
E-11
58
Engine water thermometer does not display normally
E-12
59
Hydraulic oil temperature gauge does not display correctly
E-13
60
Fuel gauge does not display correctly
E-14
61
Swing lock monitor does not display correctly
E-15
62
When monitor switch is operated, nothing is displayed
E-16
63
Windshield wiper and window washer do not work
E-17
64
Alarming buzzer cannot be cancelled
E-18
PC750, 800-7
20-215 (1)
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting No.
Failure-looking phenomenon
Code display
E mode
H mode
S mode
Monitor panel-related failure (Service Menu: Special Function Display) 65
"Boom RAISE" is not correctly displayed in monitor function
E-19
66
"Boom LOWER" is not correctly displayed in monitor function
E-20
67
"Arm IN" is not correctly displayed in monitor function
E-21
68
"Arm OUT" is not correctly displayed in monitor function
E-22
69
"Bucket CURL" is not correctly displayed in monitor function
E-23
70
"Bucket DUMP" is not correctly displayed in monitor function
E-24
71
"SWING" is not correctly displayed in monitor function
E-25
72
"Left travel" is not displayed normally in monitoring function
E-26
73
"Right travel" is not displayed normally in monitoring function
E-27
74
"Service" is not correctly displayed in monitor function
E-28
Other failure 75
Air conditioner does not work
E-29
76
Step light does not light up or go off
E-30
77
Electric grease gun does not operate
E-31
20-216 (1)
PC750, 800-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM Connector table Connector No. A01 A02 A03 A05 A06 A07 A09 A10 A11 A12 A13 A14 B B01 B02 B03 B11 B12 B13 B14 B15 B16 B17 B18 B19 B21 B22 B23 B24 B25 B26 B27 B28 B29 BR C01 C02 C03 C09 C13 CN1 CN2 CN3 CN4 CN5 CN6
Connector No. of Type pin X X DT DT DT SWP SWP DT DT DT DT DT Terminal HD30 DT DT Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal DRC DRC DRC S DT DT DT DT DT DT DT
PC750, 800-7
4 4 6 12 12 16 8 6 12 12 12 12 2 21 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 24 40 40 8 2 2 2 2 2 2 2
Place of use Intermediate connector Intermediate connector Intermediate connector Intermediate connector (Gray) Intermediate connector (Green) Intermediate connector (Black) Intermediate connector (Gray) Intermediate connector Intermediate connector (Black) Intermediate connector (Green) Intermediate connector (Gray) Intermediate connector (Black) Battery relay terminal B Circuit breaker box Circuit breaker box Circuit breaker box Circuit breaker 1 Circuit breaker 2 Circuit breaker 3 Circuit breaker 4 Circuit breaker 5 Circuit breaker 6 Circuit breaker 7 Circuit breaker 8 Circuit breaker 9 Circuit breaker 1 Circuit breaker 2 Circuit breaker 3 Circuit breaker 4 Circuit breaker 5 Circuit breaker 6 Circuit breaker 7 Circuit breaker 8 Circuit breaker 9 Battery relay terminal BR Pump controller Pump controller Pump controller Model selection connector (for pump controller) TVC solenoid No. 1 fuel injector No. 2 fuel injector No. 3 fuel injector No. 4 fuel injector No. 5 fuel injector No. 6 fuel injector
Stereogram S-1 T-1 N-2 T-1 N-1 S-1 N-2 O-1 S-1 T-1 S-9 T-9 B-9 A-2 D-9 A-1 A-2
Address M E circuit circuit H-7 H-6 H-6 H-5 H-5 H-4
J-7 K-8 K-8 K-8 L-8 L-8
E-7 E-7 E-6 E-5 E-4 I-1 I-1
P circuit G-7 G-7 G-7 G-6 G-6 G-5 G-5 G-5
L-7 K-7 K-7 K-7 L-7 L-7
L-8 L-7
J-1 J-1
L-7 L-7 L-7
L-8 L-8
L-7 L-8 L-7
J-1 J-1
L-7 A-2 A-6 V-9 W-9 W-9 W-6 L-6 AF-7 AG-8 AH-8 AI-8 AI-8 AI-7
J-7 A-3 A-3 A-2
H-1 A-8 A-8
L-7 L-7 A-8 A-7 A-6 B-1 L-4
K-4 K-3 K-4 K-3 K-4 K-3
20-217 (1)
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TROUBLESHOOTING
a The addresses roughly show the places of the connectors in the 3-dimensional connectors arrangement drawing and the electric circuit diagram of each system. Connector Connector No. of No. Type pin
Place of use
Stereogram W-7 W-7 R-1 Q-1 Q-1 Q-1 S-9 S-9 A-7 O-8 W-5 V-1 V-1 V-1 AJ-4 AJ-3 AJ-6 L-8 AA-9 W-3 AH-2 A-5 A-3 W-4 W-4
D01 D02 D03 D04 D05 D06 D07 D08 E E06 E09 E11 E12 E13 E21 E22 ENE F01 F02 FB1 G G11 G12 H08 H09
SWP SWP SWP SWP SWP SWP KES1 KES1 Terminal M S DRC DRC DRC HD30 HD30 DT X YAZAKI — YAZAKI X X M S
8 8 8 8 8 8 2 2 1 3 8 24 40 40 31 31 2 2 2 — 2 2 2 8 8
Assembled-type diode Assembled-type diode Assembled-type diode Assembled-type diode Assembled-type diode Assembled-type diode Diode Diode Battery relay terminal E Fuel control dial Model selection connector (for engine controller) Engine controller Engine controller Engine controller Intermediate connector Intermediate connector Engine speed sensor Travel alarm Intermediate connector Fuse box Engine G sensor Electric grease gun Electric grease gun remote switch Intermediate connector Intermediate connector
H10
S
16
Intermediate connector
T-9
H11
S
16
Intermediate connector
T-9
H12 H15 HT J01 J02 J03 J04 J05 J06 J07 J08 J09 J11 J12 J13 J14 J15 J16 J17 J18
S S090 Terminal J J J J J J J J J DT DT DT DT DT DT DT DT
12 20 3 20 20 20 20 20 20 20 20 20 8 8 8 8 8 8 8 6
Intermediate connector Intermediate connector Heater relay Joint connector (Black) Joint connector (Black) Joint connector (Pink) Joint connector (Green) Joint connector (Pink) Joint connector (Orange) Joint connector (Green) Joint connector (Pink) Joint connector (Black) Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector
U-9 N-7 AJ-5 W-8 W-8 W-8 W-7 W-6 W-6 V-9 U-9 X-2 L-8 L-6 K-2 L-5 J-9 J-9 K-9 F-9
20-218 (1)
Address M E circuit circuit E-9 F-9
F-9 F-9
J-7
K-2 K-1
J-4
H-2 K-8 A-1 A-7 A-6 A-4 I-4 I-7
H-7
P circuit A-4 A-3 A-3 A-3 A-2 E-9 E-9 L-7
F-4 F-3
K-6 L-6 L-5 G-8
K-5
D-7 D-7 B-1 D-6 B-1 D-5 D-4 D-3 K-2 C-9 C-9 D-9 D-9 E-9
D-1 J-8
E-2 E-2
J-7 I-9
E-2 A-2
G-9 G-9
A-9 A-9 B-9 B-9 C-9 C-9 D-9 D-9
E-9 G-9 D-9
I-9
H-9
H-9 H-9 I-9 I-9 I-9
H-9 I-9 I-9
I-9
PC750, 800-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TROUBLESHOOTING
Connector Connector No. of No. Type pin
Place of use
Stereogram H-1 L-7 I-9 D-1 U-2 W-2 N-4 C-9 P-8 B-9 A-9 E-9 AC-8 C-1 B-1 N-3 U-2 N-7 W-5 I-1 U-2 S-9 W-3 AG-2 D-1 C-1 R-9 W-4 Z-8 Y-7 A-3 U-2 N-3 Z-8 U-2 AD-8 AB-1 V-9 E-1 AD-2 E-1 D-1 AJ-4 AH-2
J19 J20 J21 J22 K19 K30 K31 M M07 M08 M09 M10 M13 M16 M17 M19 M21 M22 M26 M28 M31 M32 M33 M34 M37 M38 M38 M39 M40 M41 M42 M45 M46 M71 M72 M73 M75 M79 M80 M81 M82 M95 NE OL
DT DT DT DT M DT DT Terminal M M M X KES0 Terminal Terminal YAZAKI PA Y090 S SWP M M M X Terminal Terminal M M YAZAKI YAZAKI M DT X M M KES0 YAZAKI YAZAKI X M M X YAZAKI DT
6 6 6 8 2 3 3 1 3 1 1 1 2 1 1 2 9 2 12 2 2 2 2 1 1 1 2 3 2 2 1 12 4 2 4 2 2 2 1 2 1 4 2 2
Joint connector Joint connector Joint connector Joint connector Pump resistor (for driving pump in emergency) CAN terminal resistor CAN terminal resistor Battery relay terminal M Light switch Working lamp (Boom) Working lamp (Boom) Intermediate connector Speaker (Right) Horn (High tone) Horn (Low tone) Cigarette lighter Radio Horn switch Air conditioner unit Windshield washer motor Optional power supply (2) Optional power supply (1) Optional power supply (3) Air conditioner compressor electromagnetic clutch Horn (High tone) Horn (Low tone) Machine push-up switch Boom shockless control switch Headlamp Headlamp Right headlamp Intermediate connector RS232C junction connector Room lamp DC/DC converter Speaker (Left) Step light 12-V accessory socket Intermediate connector Step light switch Flash light Intermediate connector Engine Ne sensor Engine oil level sensor
P01
070
12
Monitor panel
N-6
P02
040
20
Monitor panel
N-5
P03 P05 P06
M M DT
2 2 2
Alarm buzzer stop switch Rotary lamp switch Fuel level sensor
P-9 W-4 C-9
PC750, 800-7
Address M E circuit circuit I-9 J-9 J-9 K-1 A-4 J-7 D-1 H-1 H-1 H-2
A-1 K-7 I-2
P circuit J-9 J-9 J-9 J-9 B-1 F-3 E-1 L-7
G-9 H-9
B-1 K-8
G-9 A-1 F-1 A-8 A-8 I-1 A-4
D-1 G-9 F-1 G-9 G-9 K-5 K-3 A-7 A-1 A-6 A-1 D-1
K-8
E-1
K-8
E-1
K-4
20-219 (1)
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TROUBLESHOOTING
Connector Connector No. of No. Type pin P08 P10 P11 P15 P16 P20 P30 P31 P70 PCV1 PCV2 PFUEL PIM PSH PSL R10 R11 R13 R14 R15 R20 R21 R22 S01 S02 S03 S04 S05 S06 S07 S08
X DT DT Y050 YAZAKI X DT DT 040 SUMI SUMI AMP SUMI Terminal Terminal R R R R R R R R X X X X X X X X
2 2 2 2 2 2 3 3 16 2 2 3 3 1 1 5 5 5 5 5 5 5 5 2 2 2 2 2 2 2 2
S09
X
2
S10 S11 S12 S13 S14 S21 S22 S25 ST T02 T03 T04 T05 T06 T06A T08 T09 T10
X X X X M Terminal Terminal S090 DT Terminal Terminal Terminal Terminal Terminal M Terminal Terminal Terminal
2 2 2 2 3 6 6 16 2 1 1 1 1 1 1 1 2 1
20-220 (1)
Place of use Radiator water level switch Hydraulic oil temperature sensor Air cleaner clogging switch Air conditioner sunlight sensor Air conditioner outside temperature sensor Radiator water level switch Front pump pressure sensor Rear pump pressure sensor Monitor panel Fuel supply pump PCV1 Fuel supply pump PCV2 Common rail pressure sensor Boost pressure sensor Engine oil pressure switch (High pressure) Engine oil pressure switch (Low pressure) Light relay Starting motor cut-out relay (PPC lock) Starting motor cut-out relay (Personal cord) Step light power supply drive relay Step light relay Horn relay Flash light relay Engine controller power supply relay Right travel forward PPC oil pressure switch Boom RAISE PPC oil pressure switch Arm OUT PPC oil pressure switch Boom LOWER PPC oil pressure switch Arm IN PPC oil pressure switch Bucket CURL PPC oil pressure switch Bucket DUMP PPC oil pressure switch Swing RIGHT PPC oil pressure switch Service PPC oil pressure switch (Intermediate connector) Swing LEFT PPC oil pressure switch Right travel reverse PPC oil pressure switch Left travel forward PPC oil pressure switch Left travel reverse PPC oil pressure switch Safety lock lever switch Emergency pump drive switch Swing holding brake release switch Intermediate connector Starting motor Revolving frame ground Revolving frame ground Revolving frame ground Floor frame ground Radio body ground Intermediate connector Engine controller ground Revolving frame ground Revolving frame ground
Stereogram L-7 L-5 I-9 N-6 H-9 L-8 H-9 J-9 N-4 AG-2 AH-2 AH-3 AG-7 AI-3 AI-3 O-8 P-8 Q-9 W-5 W-5 W-6 W-7 W-5 G-1 K-2 L-3 K-2 L-3 L-2 L-2 L-4
Address M E circuit circuit K-5 K-6 K-5
P circuit
K-5
A-5
K-7 K-3 K-2 K-7 K-6 L-5 L-6
L-5 L-5 E-1
G-1 G-1 H-1 F-9 E-9 E-9 E-9 B-9 K-3 K-2 K-2 K-2 K-2 K-2 K-2 K-2
J-1
K-1
L-3 H-1 H-1 I-1 S-1 R-9 R-9 Q-9 AH-8 A-6 A-6 A-4 W-3 T-2 T-1 V-1 A-4 F-1
K-1 K-1 K-1 K-1 F-9 C-1 D-1
F-2
K-4 K-6 K-6
K-6 K-8 K-8 G-1
F-7
D-2
A-1 L-6
K-8 H-8
PC750, 800-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TROUBLESHOOTING
Connector Connector No. of No. Type pin
Place of use
T11 T12 T14 THL TWH TWL V01 V02 V03 V04 V05 V06 V07 V08 V09 V10 W03
Terminal Terminal Terminal DT DT DT DT DT DT DT DT DT DT DT DT DT X
1 1 2 3 2 3 2 2 2 2 2 2 2 2 2 2 2
Stereogram Cab ground AD-3 Revolving frame ground A-4 Revolving frame ground A-4 Spill fuel temperature sensor AI-3 Engine water temperature sensor (High temperature) AE-7 Engine water temperature sensor (Low temperature) AF-7 Swing priority solenoid valve G-1 2-stage relief solenoid valve L-8 Travel junction solenoid valve L-5 Swing holding brake solenoid valve F-9 Machine push-up solenoid valve G-9 Travel speed selector solenoid valve G-9 CO cancel solenoid valve L-4 PPC oil pressure lock solenoid valve G-1 Boom shockless control solenoid valve (Raise) J-1 Boom shockless control solenoid valve (Lower) J-1 Window rear limit switch [Single-wiper specification] AB-9
W04
M
6
Wiper motor
Y-4
W05 W06 X05
M M M
6 2 4
Lower wiper motor [Double-wiper specification] Lower wiper switch [Double-wiper specification] Swing lock switch
E-1 W-4 Q-9
Connector type DT
Address M E circuit circuit L-6
G-2 G-2 G-2 G-2 G-2 G-2 G-1 G-1 G-1 G-1 A-9 B-2 B-7 G-9 E-1 E-1
Japanese and German makes DT type connector (08192-XXXXX)
M
Product of Yazaki M type connector (08056-0XXXX)
R
Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S
Product of Yazaki S type connector (08056-1XXXX)
X
Product of Yazaki X type connector (08055-0XXXX)
PA
Product of Yazaki PA type connector
SWP
Product of Yazaki SWP type connector (08055-1XXXX)
DRC
Japanese and German makes DRC type connector
040
Product of Japan 040 type connector
070
Product of Japan 070 type connector
Y050
Product of Yazaki 050 type connector
S090
Product of Sumitomo 090 type connector
Y090
Product of Yazaki 090 type connector
Terminal
Yazaki-made connector KES0 type connector (08027-0XXXX) Round pin type or single terminal connector
KES1
KES1 type connector (08027-1XXXX)
HD30
Japanese and German makes HD30 type connector (08191-XXXXX)
AMP
Product of Japan AMP type connector
SUMI
Product of Sumitomo-made connector
PC750, 800-7
A-1
Detailed information Product of Sumitomo Wiring Systems 090 type splice
KES0
K-8 G-1 K-4 K-6 K-6
J
YAZAKI
P circuit
20-221 (1)
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
Connector Location Stereogram
20-222 (1)
PC750, 800-7
TROUBLESHOOTING
PC750, 800-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
20-223 (1)
TROUBLESHOOTING
20-224 (1)
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
PC750, 800-7
TROUBLESHOOTING
PC750, 800-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
20-225 (1)
TROUBLESHOOTING
20-226 (1)
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
PC750, 800-7
TROUBLESHOOTING
PC750, 800-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
20-227 (1)
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
Monitor Panel System Circuit Diagram (M Circuit)
20-228 (1)
PC750, 800-7
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
a This circuit diagram is made by extracting the monitor panel system, engine preheating/starting/charging system, light system, and communication network system from the general electric circuit diagram.
PC750, 800-7
20-229 (1)
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
Engine Control System Circuit Diagram (E Ciruit)
20-230 (1)
PC750, 800-7
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
a This circuit diagram is made by extracting the engine controller system from the general electric circuit diagram.
PC750, 800-7
20-231 (1)
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
Pump Controller System Circuit Diagram (P Circuit)
20-232 (1)
PC750, 800-7
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
a This circuit diagram is made by extracting the pump controller system, PPC lock solenoid system, machine push-up solenoid system, and boom shockless solenoid system from the general electric circuit diagram.
PC750, 800-7
20-233 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS a The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing.
X type connector
No.of pins
Male (female housing)
Female (male housing)
T-adapter Part No.
1
Part No.: 08055-00181
Part No.: 08055-00191
799-601-7010
2
799-601-7020
Part No.: 08055-00282
Part No.: 08055-00292
3
799-601-7030
Part No.: 08055-00381
Part No.: 08055-00391
4
799-601-7040
Part No.: 08055-00481
Part No.: 08055-00491
—
Terminal part No.: 79A-222-3370 • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20
Terminal part No.: 79A-222-3390 • Electric wire size: 0.85 • Grommet: Black • Q’ty : 20
—
—
Terminal part No.: 79A-222-3380 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20
Terminal part No.: 79A-222-3410 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20
—
20-234 (1)
PC750, 800-7
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
SWP type connector Male (female housing)
Female (male housing)
6
799-601-7050
Part No.: 08055-10681
Part No.: 08055-10691
8
799-601-7060
Part No.: 08055-10881
Part No.: 08055-10891
12
799-601-7310
Part No.: 08055-11281
Part No.: 08055-11291
14
799-601-7070
Part No.: 08055-11481
PC750, 800-7
T-adapter Part No.
Part No.: 08055-11491
20-235 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
SWP type connector
No. of pins
Male (female housing)
Female (male housing)
16
T-adapter Part No.
799-601-7320
Part No.: 08055-11681
Part No.: 08055-11691
—
Terminal part No.: • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20
Terminal part No.: • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20
—
—
Terminal part No.: • Electric wire size: 1.25 • Grommet: Red • Q’ty: 20
Terminal part No.: • Electric wire size: 1.25 • Grommet: Red • Q’ty: 20
—
20-236 (1)
PC750, 800-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M type connector
No.of pins
Male (female housing)
Female (male housing)
T-adapter Part No.
1
Part No.: 08056-00171
Part No.: 08056-00181
799-601-7080
2
799-601-7090
Part No.: 08056-00271
Part No.: 08056-00281
3
799-601-7110
Part No.: 08056-00371
Part No.: 08056-00381
4
799-601-7120
Part No.: 08056-00471
Part No.: 08056-00481
6
799-601-7130
Part No.: 08056-00671
Part No.: 08056-00681
8
799-601-7340
Part No.: 08056-00871
PC750, 800-7
Part No.: 08056-00881
20-237 (1)
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector Male (female housing)
Female (male housing)
8
799-601-7140
Part No.: 08056-10871
Part No.: 08056-10881
10 (White)
799-601-7150
Part No.: 08056-11071
Part No.: 08056-11081
12 (White)
799-601-7350
Part No.: 08056-11271
Part No.: 08056-11281
16 (White)
799-601-7330
Part No.: 08056-11671
20-238 (1)
T-adapter Part No.
Part No.: 08056-11681
PC750, 800-7
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector Male (female housing)
Female (male housing)
10 (Blue)
—
—
—
12 (Blue)
799-601-7160
Part No.: 08056-11272
Part No.: 08056-11282
16 (Blue)
799-601-7170
Part No.: 08056-11672
PC750, 800-7
T-adapter Part No.
Part No.: 08056-11682
20-239 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
MIC type connector
No.of pins
Male (female housing)
Female (male housing)
T-adapter Part No.
7
Body part No.: 79A-222-2640 (Q’ty: 5)
Body part No.: 79A-222-2630 (Q’ty: 5)
—
11
Body part No.: 79A-222-2680 (Q’ty: 5)
Body part No.: 79A-222-2670 (Q’ty: 5)
—
5
799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5)
Body part No.: 79A-222-2610 (Q’ty: 5)
9
799-601-2950
Body part No.: 79A-222-2660 (Q’ty: 5)
Body part No.: 79A-222-2650 (Q’ty: 5)
13
799-601-2720
Body part No.: 79A-222-2710 (Q’ty: 2)
20-240 (1)
Body part No.: 79A-222-2690 (Q’ty: 2)
PC750, 800-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
MIC type connector
No.of pins
Male (female housing)
Female (male housing)
17
T-adapter Part No.
799-601-2730
Body part No.: 79A-222-2730 (Q’ty: 2)
Body part No.: 79A-222-2720 (Q’ty: 2)
21
799-601-2740
Body part No.: 79A-222-2750 (Q’ty: 2)
Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770 (Q’ty: 50)
Terminal part No.: 79A-222-2760 (Q’ty: 50)
PC750, 800-7
—
20-241 (1)
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
AMP040 type connector Male (female housing)
Female (male housing)
8
T-adapter Part No.
799-601-7180
—
Housing part No.: 79A-222-3430 (Q’ty: 5)
12
799-601-7190
—
Housing part No.: 79A-222-3440 (Q’ty: 5)
16
799-601-7210
—
Housing part No.: 79A-222-3450 (Q’ty: 5)
20
799-601-7220
—
Housing part No.: 79A-222-3460 (Q’ty: 5)
a Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-242 (1)
PC750, 800-7
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
AMP070 type connector Male (female housing)
Female (male housing)
10
799-601-7510
—
Part No.: 08195-10210
12
799-601-7520
—
Part No.: 08195-12210
14
799-601-7530
—
Part No.: 08195-14210
18
799-601-7540
—
Part No.: 08195-18210
20
799-601-7550
—
PC750, 800-7
T-adapter Part No.
Part No.: 08195-20210
20-243 (1)
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L type connector Male (female housing)
Female (male housing)
2
—
—
No.of pins
—
Connector for PA Male (female housing)
Female (male housing)
9
—
Bendix MS connector Male (female housing)
Female (male housing)
10
(1)
T-adapter Part No.
799-601-3460
—
20-244
T-adapter Part No.
—
—
No.of pins
T-adapter Part No.
—
PC750, 800-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
KES 1 (Automobile) connector
No.of pins
Male (female housing)
Female (male housing)
2
T-adapter Part No.
—
Part No.: 08027-10210 (Natural color) 08027-10220 (Black)
Part No.: 08027-10260 (Natural color) 08027-10270 (Black)
3
—
Part No.:08027-10310
Part No.:08027-10360
4
—
Part No.: 08027-10410 (Natural color) 08027-10420 (Black)
Part No.: 08027-10460 (Natural color) 08027-10470 (Black)
6
—
Part No.: 08027-10610 (Natural color) 08027-10620 (Black)
PC750, 800-7
Part No.: 08027-10660 (Natural color) 08027-10670 (Black)
20-245 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
KES 1 (Automobile) connector
No.of pins
Male (female housing)
Female (male housing)
8
—
Part No.: 08027-10810 (Natural color) 08027-10820 (Black)
No.of pins
Part No.: 08027-10860 (Natural color) 08027-10870 (Black)
Connector for relay (Socket type) Male (female housing)
Female (male housing)
5
—
6
799-601-7370
—
20-246
T-adapter Part No.
799-601-7360
—
(1)
T-adapter Part No.
—
PC750, 800-7
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
F type connector Male (female housing)
Female (male housing)
4
—
—
PC750, 800-7
T-adapter Part No.
—
20-247 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter Part No.
799-601-9210
18-8 (1)
Part No.: 08191-11201, 08191-11202, 08191-11205, 08191-11206 Pin (female terminal)
Part No.: 08191-14101, 08191-14102, 08191-14105, 08191-14106 Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, 08191-12205, 08191-12206 Pin (male terminal)
Part No.: 08191-13101, 08191-13102, 08191-13105, 08191-13106 Pin (female termial)
799-601-9220
Part No.: 08191-21201, 08191-12202, 08191-21205, 08191-12206 18-14 (2) Pin (female terminal)
Part No.: 08191-24101, 08191-24102, 08191-24105, 08191-24106 Pin (male termial)
799-601-9220
Part No.: 08191-22201, 08191-22202, 08191-22205, 08191-22206
20-248 (1)
Part No.: 08191-23101, 08191-23102, 08191-23105, 08191-23106
PC750, 800-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter Part No.
799-601-9230
18-20 (3)
Part No.:08191-31201, 08191-31202
Part No.:08191-34101, 08191-34102
Pin (female terminal)
Pin (male termial)
799-601-9230
Part No.:08191-32201, 08191-32202
Part No.:08191-33101, 08191-33102
Pin (male terminal)
Pin (female termial)
799-601-9240
18-21 (4)
Part No.:08191-41201, 08191-42202
Part No.:08191-44101, 08191-44102
Pin (female terminal)
Pin (male termial)
799-601-9240
Part No.:08191-42201, 08191-42202
PC750, 800-7
Part No.:08191-43101, 08191-43102
20-249 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter Part No.
799-601-9250
24-9 (5)
Part No.:08191-51201, 08191-51202
Part No.:08191-54101, 08191-54102
Pin (female terminal)
Pin (male termial)
799-601-9250
Part No.:08191-52201, 08191-52202
Part No.:08191-53101, 08191-53102
Pin (male terminal)
Pin (female termial)
799-601-9260
Part No.: 08191-61201, 08191-62202, 08191-61205, 08191-62206 24-16 (6) Pin (female terminal)
Part No.: 08191-64101, 08191-64102, 08191-64105, 08191-64106 Pin (male termial)
799-601-9260
Part No.: 08191-62201, 08191-62202, 08191-62205, 08191-62206
20-250 (1)
Part No.: 08191-63101, 08191-63102, 08191-63105, 08191-63106
PC750, 800-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter Part No.
799-601-9270
24-21 (7)
Part No.: 08191-71201, 08191-71202, 08191-71205, 08191-71206 Pin (female terminal)
Part No.: 08191-74101, 08191-74102, 08191-74105, 08191-74106 Pin (male termial)
799-601-9270
Part No.: 08191-72201, 08191-72202, 08191-72205, 08191-72206 Pin (male terminal)
Part No.: 08191-73101, 08191-73102, 08191-73105, 08191-73106 Pin (female termial)
799-601-9280
Part No.: 08191-81201, 08191-81202 08191-81203, 08191-81204 08191-81205, 08191-80206 24-22 (8) Pin (female terminal)
Part No.: 08191-84101, 08191-84103, 08191-84105,
08191-84102 08191-84104 08191-84106
Pin (male termial)
799-601-9280
Part No.: 08191-82201, 08191-82203, 08191-82205,
PC750, 800-7
08191-82202 08191-82204 08191-82206
Part No.: 08191-83101, 08191-83103, 08191-83105,
08191-83102 08191-83104 08191-83106
20-251 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male termial)
Pin (female terminal)
T-adapter Part No.
799-601-9290
24-31 (9)
Part No.: 08191-91203, 08191-91204, 08191-91205, 08191-91206 Pin (female terminal)
Part No.: 08191-94103, 08191-94104, 08191-94105, 08191-94106 Pin (male termial)
799-601-9290
Part No.: 08191-92203, 08191-92204, 08191-92205, 08191-92206
20-252 (1)
Part No.: 08191-93103, 08191-93104, 08191-93105, 08191-93106
PC750, 800-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector
No.of pins
Body (plug)
Body (receptacle)
2
T-adapter Part No.
799-601-9020
Part No.: 08192-12200 (normal type) 08192-22200 (fine wire type)
Part No.: 08192-12100 (normal type) 08192-22100 (fine wire type)
3
799-601-9030
Part No.: 08192-13200 (normal type) 08192-23200 (fine wire type)
Part No.: 08192-13100 (normal type) 08192-23100 (fine wire type)
4
799-601-9040
Part No.: 08192-14200 (normal type) 08192-24200 (fine wire type)
Part No.: 08192-14100 (normal type) 08192-24100 (fine wire type)
6
799-601-9050
Part No.: 08192-16200 (normal type) 08192-26200 (fine wire type)
PC750, 800-7
Part No.: 08192-16100 (normal type) 08192-26100 (fine wire type)
20-253 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector
No.of pins
Body (plug)
Body (receptacle)
8GR: 8B: 8G: 8BR:
8
Part No.: 08192-1820 08192-2820
(normal type) Part No.: 08192-1810 (fine wire type) 08192-2810
799-601-9060 799-601-9070 799-601-9080 799-601-9090
(normal type) (fine wire type)
12GR: 12B: 12G: 12BR:
12
Part No.: 08192-1920 08192-2920
20-254 (1)
T-adapter Part No.
(normal type) Part No.: 08192-1910 (fine wire type) 08192-2910
799-601-9110 799-601-9120 799-601-9130 799-601-9140
(normal type) (fine wire type)
PC750, 800-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] DTM Series connector
No.of pins
Body (plug)
Body (receptacle)
T-adapter Part No.
799-601-9010
2
Part No.: 08192-02200
Part No.: 08192-02100
[The pin No. is also marked on the connector (electric wire insertion end)] DTHD Series connector
No.of pins
Body (plug)
Body (receptacle)
2
T-adapter Part No.
—
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12) 08192-41200 (Contact size #8) 08192-41100 (Contact size #8) 08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC750, 800-7
20-255 (1)
TROUBLESHOOTING
T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE
799-601-2600 799-601-3100 799-601-3200 799-601-3300 799-601-3360 799-601-3370 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780 799-601-2790 799-601-2810 799-601-2820 799-601-2830 799-601-2840 799-601-2850 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799-601-7060 799-601-7310 799-601-7070 799-601-7320 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340
20-256 (1)
Measurement box Measurement box Measurement box Measurement box Plate Plate Plate BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) Case MIC MIC MIC MIC MIC ECONO ECONO ECONO ECONO ECONO DLI DLI DLI Additional cable Case X X X X SWP SWP SWP SWP SWP M M M M M M
—
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
799-601-2900
799-601-2800
Connector type or No. of pins part name
799-601-2700
Part No.
799-601-2500
a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part number of Harness Checker Ass'y.
Econo-21P MS-37P MS-37P Econo-24P For MS box For MS box For MS box 24P 24P 17P 17P 5P 10P 5P 14P 19P 14P 5P 13P 17P 21P 9P 2P 3P 4P 8P 12P 8P 12P 16P 1P 2P 3P 4P 6P 8P 12P 14P 16P 1P 2P 3P 4P 6P 8P
PC750, 800-7
799-601-7140 799-601-7150 799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601-9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9210 799-601-9220 799-601-9230 799-601-9240 799-601-9250 799-601-9260 799-601-9270 799-601-9280 799-601-9290 799-601-9310 799-601-9320 799-601-9330 799-601-9340 799-601-9350 799-601-9360 799-601-9410
S S S S S S AMP040 AMP040 AMP040 AMP040 Short connector Case Case 070 070 070 070 070 Relay connector Relay connector JFC connector DTM DT DT DT DT DT DT DT DT DT DT DT DT HD30 HD30 HD30 HD30 HD24 HD30 HD30 HD30 HD30 Plate Measurement box Case Case DEUTSCH DEUTSCH For NE, G sensor For fuel, boost 799-601-9420 press. 799-601-9430 PVC socket
PC750, 800-7
—
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
799-601-2900
799-601-2800
Connector type or No. of pins part name
799-601-2700
Part No.
T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
TROUBLESHOOTING
8P 10P-White 12P-Blue 16P-Blue 16P-White 12P-White 8P 12P 16P 20P X-2 10P 12P 14P 18P 20P 5P 6P 2P 2P 2P 3P 4P 6P 8P-Gray 8P-Black 8P-Green 8P-Brown 12P-Gray 12P-Black 12P-Green 12P-Brown 18-8 18-14 18-20 18-21 24-9 24-16 24-21 24-23 24-31 For HD30 For DT, HD 40P 24P 2P 3P 2P
20-257 (1)
TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE DISPLAYED BEFORE CARRYING OUT TROUBLESHOOTING AFTER AN ERROR OR A FAILURE CODE IS DISPLAYED ...................................................................................................... 20-304 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-306 Error Code in Electrical System E112 (Wiper Drive (For) S/C) ................................................................... 20-308 Error Code in Electrical System E113 (Wiper Drive (Rev) S/C) .................................................................. 20-312 Error Code in Electrical System E114 (Washer Drive S/C) ......................................................................... 20-314 Error Code in Electrical System E115 (Wiper Working Abnormality) .......................................................... 20-316 Error Code in Electrical System E116 (Wiper Parking Abnormality) ........................................................... 20-318 Error Code in Electrical System E117 (Eng. Controller S-NET Comm Err.)................................................ 20-322 Error Code in Electrical System E118 (Pump Controller S-NET Comm Err.).............................................. 20-324 Error Code in Electrical System E128 (Monitor Comm. Abnormality)......................................................... 20-326 Error Code in Electrical System E201 (CO Cancel Sol. S/C)...................................................................... 20-328 Error Code in Electrical System E202 (Travel Junction Sol. S/C) ............................................................... 20-330 Error Code in Electrical System E203 (Swing Brake Sol. S/C) ................................................................... 20-332 Error Code in Electrical System E204 (2-stage Relief Sol. S/C) ................................................................. 20-334 Error Code in Electrical System E205 (Swing Priority Sol. S/C) ................................................................. 20-336 Error Code in Electrical System E206 (Travel Speed Sol. S/C).................................................................. 20-338 Error Code in Electrical System E207 (Flash Light Relay S/C)................................................................... 20-340 Error Code in Electrical System E211 (CO Cancel Sol. Disc.).................................................................... 20-342 Error Code in Electrical System E212 (Travel Junction Sol. Disc.)............................................................. 20-344 Error Code in Electrical System E213 (Swing Brake Sol. Disc.) ................................................................. 20-346 Error Code in Electrical System E214 (2-stage Relief Sol. Disc.) ............................................................... 20-348 Error Code in Electrical System E215 (Swing Priority Sol. Disc.) ............................................................... 20-350 Error Code in Electrical System E216 (Travel Speed Sol. Disc.) ................................................................ 20-352 Error Code in Electrical System E217 (Model selection Abnormality) ........................................................ 20-354 Error Code in Electrical System E218 (S-Net Comm. Disc.)....................................................................... 20-356 Error Code in Electrical System E221 (Travel Alarm S/C) .......................................................................... 20-358 Error Code in Electrical System E224 (F Pump P. Sensor Abnormality) .................................................... 20-360 Error Code in Electrical System E225 (R Pump P. Sensor Abnormality) .................................................... 20-362 Error Code in Electrical System E226 (Press. Sensor Power Abnormality)................................................ 20-364 Error Code in Electrical System E227 (Engine Speed Sensor Abnormality) .............................................. 20-366 Error Code in Electrical System E232 (TVC Sol. S/C) ................................................................................ 20-368 Error Code in Electrical System E233 (TVC Sol. Disc.) .............................................................................. 20-370 Error Code in Electrical System E257 (Pump Comm. Abnormality) ........................................................... 20-372 Error Code in Electrical System E302 (Step Light Relay S/C) .................................................................... 20-374 Error Code in Electrical System E304 (Step Light Power Hold Relay S/C) ................................................ 20-376 Error Code in Electrical System E315 (Battery Relay Drive S/C) ............................................................... 20-378 Error Code in Electrical System E91B (Engine Ne sensor problem) .......................................................... 20-380 Error Code in Electrical System E91C (Engine G sensor problem) ............................................................ 20-381 Error Code in Electrical System E920 (Engine type selection error)........................................................... 20-382 Error Code in Electrical System E921 (Engine type mismatch) .................................................................. 20-384 Error Code in Electrical System E931 (Fuel dial sys. error)........................................................................ 20-386 Error Code in Electrical System E934 (Engine coolant sensor Hi error)..................................................... 20-388 Error Code in Electrical System E936 (Engine oil press. sw. error) ............................................................ 20-390 Error Code in Electrical System E93C (Engine boost sensor error) ........................................................... 20-392
PC750, 800-7
20-301 (1)
TROUBLESHOOTING
Error Code in Electrical System E93D (Engine fuel temp. sensor error) .................................................... 20-394 Error Code in Electrical System E953 (Engine Comm. Abnormality).......................................................... 20-396 Error Code in Electrical System E954 (Short engine starter sw.)................................................................ 20-398 Error Code in Electrical System E955 (Engine S-NET error) ...................................................................... 20-400 Error Code in Electrical System E956 (Engine power failure (1)) ............................................................... 20-402 Error Code in Electrical System E957 (Engine power failure (2)) ............................................................... 20-404 Error Code in Electrical System E95A (Engine Q-adj. sw. signal error) ...................................................... 20-406 Error Code in Electrical System E96A (Engine coolant sensor Lo error).................................................... 20-408 Error Code in Electrical System E970 (PCV1 over current)........................................................................ 20-410 Error Code in Electrical System E971 (PCV2 over current)........................................................................ 20-412 Error Code in Electrical System E974 (PCV1 line cut)................................................................................ 20-414 Error Code in Electrical System E975 (PCV2 line cut)................................................................................ 20-416 Error Code in Electrical System E977 (Rail press. sensor error) ................................................................ 20-418 Error Code in Electrical System E979 (Rail press. high)............................................................................. 20-420 Error Code in Electrical System E97A (Rail press. abnormal) .................................................................... 20-420 Error Code in Electrical System E97B (Rail press. low).............................................................................. 20-421 Error Code in Electrical System E97C (Rail press. too low) ....................................................................... 20-423 Error Code in Electrical System E97D (Rail press. out of control) .............................................................. 20-423 Error Code in Electrical System E980 (Eng. Controller Abnormality) ......................................................... 20-424 Error Code in Electrical System E981 (Fuel Injector 1 Disc.)...................................................................... 20-426 Error Code in Electrical System E982 (Fuel Injector 2 Disc.)...................................................................... 20-427 Error Code in Electrical System E983 (Fuel Injector 3 Disc.)...................................................................... 20-428 Error Code in Electrical System E984 (Fuel Injector 4 Disc.)...................................................................... 20-429 Error Code in Electrical System E985 (Fuel Injector 5 Disc.)...................................................................... 20-430 Error Code in Electrical System E986 (Fuel Injector 6 Disc.)...................................................................... 20-431 Error Code in Electrical System E98A (Fuel Injector 1 – 3 S/C) ................................................................. 20-432 Error Code in Electrical System E98B (Fuel Injector 4 – 6 S/C) ................................................................. 20-434 Failure Code in Mechanical System A000N1 (Eng. Hi Out of Std) ............................................................. 20-437 Failure Code in Mechanical System AA10NX (Aircleaner Clogging) .......................................................... 20-438 Failure Code in Mechanical System AB00KE (Charge Voltage Low) ......................................................... 20-440 Failure Code in Mechanical System B@BAZG (Eng. Oil Press. Low)........................................................ 20-442 Failure Code in Mechanical System B@BAZK (Eng. Oil Level Low).......................................................... 20-444 Failure Code in Mechanical System B@BCNS (Eng. Water Overheat)...................................................... 20-445 Failure Code in Mechanical System B@BCZK (Eng. Water Lvl Low)......................................................... 20-446 Failure Code in Mechanical System B@HANS (Hydr. Oil Overheat).......................................................... 20-448 Failure Code in Mechanical System DA80MA (Auto. Lub Abnormal.) ........................................................ 20-450
20-302 (1)
PC750, 800-7
TROUBLESHOOTING
BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE
BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE Connection table of circuit breakers a This connection table shows the devices to which each power supply of the circuit breakers supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). a When carrying out troubleshooting for a displayed code, you should check the circuit breakers to see if the power is supplied normally. Type of power supply
Circuit breaker No. 1 2 Switch power supply 3 (Battery relay terminal M) 4 5 6 Constant power 7 supply (Battery relay 8 terminal B) 9
20-304 (1)
Circuit breaker capacity 40A 20A 20A 20A 20A 20A 20A 20A 20A
Destination of power Fuse box (Fuses No. 1 – 15) Boom working lamp, right head lamp Grease pump Pump controller power source Head lamp on cab Starting switch and engine controller (Power supply control) Engine controller (Power supply drive) Monitor panel Fuse box (Fuses No. 16 – 20)
PC750, 800-7
TROUBLESHOOTING
BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE
Connection table of fuse boxes a This connection table shows the devices to which each power supply of the fuse boxes supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). a When carrying out troubleshooting for a displayed code, you should check the fuse boxes to see if the power is supplied normally. Type of power supply
Switch power supply (Circuit breaker 1)
Switch power supply (Circuit breaker 1)
Switch power supply (Circuit breaker 1)
Constant power supply (Circuit breaker 9)
PC750, 800-7
Fuse No.
Fuse capacity
1
10A
2
10A
3
10A
4
20A
5
10A
6 7 8 9 10 11 12 13 14 15 16 17 18 19
10A 10A 10A 10A 20A 25A 20A 20A 10A 10A 10A 10A 10A 10A
20
10A
Destination of power TVC solenoid (for emergency pump drive) Swing holding brake solenoid (for swing brake release) Starting motor cut-out relay Machine push-up solenoid Boom shockless solenoid PPC lock solenoid Cigarette lighter Windshield washer motor Horn Flash light (Spare) Rotary lamp (Spare) Radio Monitor panel Air conditioner unit (Spare) (Spare) Service power supply (M32 connector) DC/DC converter Radio — (Engine compartment lamp) Room lamp Step light Pump controller power source (for step light) Step light switch
20-305 (1)
TROUBLESHOOTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their contents fully before proceeding to actual troubleshooting work. User Code
Error Code
Failure Code
Display in monitor panel
Display in monitor panel
Display in monitor panel
Failure content
Failure phenomenon
Title of failure phenomenon shown in failure history
Failure status as detected by monitor panel or controller
Response from Action taken by the monitor panel or controller to protect an affected system or equipment, when they monitor panel detect some failure. or controller Phenomenon occurring on machine
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or controller
Relative information
Information on the failure occurred as well as the troubleshooting Cause
1
Presumed cause and standard value in normalcy
2
Cause that presumably triggered failure in question 3 (The assigned No. is for filing purpose only. It does not stand for any priority) 4
5
20-306 (1)
Standard value in normalcy and references for troubleshooting
• Standard value in normalcy by which to pass "Good" or "No good" judgement over the presumed cause • Reference for passing the above "Good" or "No Good" judgement
• Disconnection There is a faulty contact at the connector or disconnection of wiring harness occurred. • Defective grounding A wiring harness that is not connected with a grounding circuit has a contact with the grounding circuit. • Short-circuiting A wiring harness that is not connected with a 24 V electric circuit has a contact with the electric circuit.
1) Connector No. display method and handling of T-adapter Insert or connect T-adapters in the following manner before starting troubleshooting unless otherwise instructed. • If there is no indication of "male" or "female" in a specific connector No., disconnect the connector and insert the T-adapter into both male and female sides. • If there is an indication of "male" or "female" in a specific connector No., disconnect the connector and connect the T-adepter with only one side of either "male" or "female". 2) Entry sequence of pin No. and handling of circuit tester lead Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the following manner unless otherwise instructed. • Connect the positive (+) lead with the pin No. indicated at the front or the wiring harness. • Connect the negative (–) lead with the pin No. indicated at the front or the wiring harness.
PC750, 800-7
TROUBLESHOOTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred. • Connector No.: Indicates (Type - numbers of a pin) (color) • Arrow: Roughly indicates the location in the machine where it is installed.
PC750, 800-7
20-307 (1)
TROUBLESHOOTING
E112
Error Code in Electrical System E112 (Wiper Drive (For) S/C) Double-wiper specification User Code
Error Code
Failure Code
—
E112
DY2DKB
Failure content
Failure phenomenon
Wiper Drive (For) S/C (Monitor panel system)
• Abnormal current flowed in the wiper motor forward rotation circuit, when power is supplied to the circuit.
Response from • Power to the wiper motor forward rotation circuit is switched OFF. monitor panel Phenomenon occurring on machine
• The wiper stops.
Relative information Cause Upper wiper motor defective 1 (Internal short-circuiting or grounding fault)
Presumed cause and standard value in normalcy
Lower wiper motor defective 2 (Internal short-circuiting or grounding fault)
Assembled-type diode 3 D06 defective (Internal short-circuiting)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W04 (female)
Continuity and resistance value
Between (3) and (1)
Continued
Between (3) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W05 (female)
Continuity and resistance value
Between (3) and (1)
Continued
Between (3) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D06 (male)
Resistance value (Continuitiy)
Between (1) and (5)
Above 1 Mz (No continuitiy)
Between (2) and (6)
Above 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 4 (Contact with grounding circuit)
Between wiring harness between P01 (female) (9) and W04 (male) (3) or between P01 (female) (9) and D06 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between P01 (female) (10), J04 and W05 (male) (3) or between P01 (female) (10) and D06 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Monitor panel defective (Upper wiper motor)
P01 Between (9) and grounding
5
Upper wiper switch OFF
Below 3 V
ON
20 – 30 V (Note)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Monitor panel defective (Lower wiper motor)
P01 Between (10) and grounding
Lower wiper switch
Voltage
OFF
Below 3 V
ON
20 – 30 V (Note)
NOTE: When the upper wiper and lower wiper are operated simultaneously: Below 3 V lar intervals)
20-308 (1)
Voltage
20 – 30 V (at regu-
PC750, 800-7
TROUBLESHOOTING
E112
Circuit diagram related to wiper motor (Double-wiper specification)
PC750, 800-7
20-309 (1)
TROUBLESHOOTING
E112
Single-wiper specification User Code
Error Code
Failure Code
—
E112
DY2DKB
Failure content
Failure phenomenon
Wiper Drive (For) S/C (Monitor panel system)
• Abnormal current flowed in the wiper motor forward rotation circuit, when power is supplied to the circuit.
Response from • Power to the wiper motor forward rotation circuit is switched OFF. monitor panel Phenomenon occurring on machine
• The wiper stops.
Relative information
Presumed cause and standard value in normalcy
Cause Windshield wiper motor defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W04 (female)
Continuity and resistance value
Between (3) and (1)
Continued
Between (3) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P01 (female) (9) and W04 (male) (3) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Monitor panel defective
P01 Between (9) and grounding
20-310 (1)
Resistance value
Windshield wiper switch
Voltage
OFF
Below 3 V
ON
Below 3 V 20 – 30 V (at constant cycle)
PC750, 800-7
TROUBLESHOOTING
E112
Electric Circuit Diagram for Windshield Wiper Motor (Single wiper spec.)
PC750, 800-7
20-311 (1)
TROUBLESHOOTING
E113
Error Code in Electrical System E113 (Wiper Drive (Rev) S/C) Single-wiper specification User Code
Error Code
Failure Code
—
E113
DY2EKB
Failure content
Failure phenomenon
Wiper Drive (Rev) S/C (Monitor panel system)
• Abnormal current flowed in the wiper motor reverse rotation circuit, when power is supplied to the circuit.
Response from • Power to the wiper motor reverse rotation circuit is switched OFF. monitor panel Phenomenon occurring on machine
• The wiper stops.
Relative information
Presumed cause and standard value in normalcy
Cause Windshield wiper motor defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female)
Continuity and resistance value
Between (1) and (3)
Continued
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P01 (female) (10) and W04 (male) (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Monitor panel defective
P01 Between (10) and grounding
20-312 (1)
Resistance value
Windshield wiper switch
Voltage
OFF
Below 3 V
ON
Below 3 V 20 – 30 V (at constant cycle)
PC750, 800-7
TROUBLESHOOTING
E113
Electric Circuit Diagram for Windshield Wiper Motor (Single wiper spec.)
PC750, 800-7
20-313 (1)
TROUBLESHOOTING
E114
Error Code in Electrical System E114 (Washer Drive S/C) User Code
Error Code
Failure Code
—
E114
DY2CKB
Failure content
Failure phenomenon
Washer Drive S/C (Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was switched ON.
Response from • Power supply to the grounding in the window washer motor circuit was switched OFF. Monitor Panel Phenomenon occurring on machine
• The window washer stopped moving.
Relative information
Presumed cause and standard value in normalcy
Cause Window washer drive 1 motor defective (Internal short-circuiting) Short-circuiting of wiring harness 2 (Contact with 24 V circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. M28 (male)
Resistance value
Between (1) and (2)
5 – 20 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness from P01 (female) (3) and M28 (female) (2), or between wiring harness between P01 (female) (3) and D05 (female) (7) and grounding
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Monitor panel defective
P01 Between (3) and grounding
20-314 (1)
Voltage
Window washer switch
Voltage
OFF
20 – 30 V
ON
Below 1 V
PC750, 800-7
TROUBLESHOOTING
E114
Electrical Circuit Diagram for Window Washer Motor
PC750, 800-7
20-315 (1)
TROUBLESHOOTING
E115
Error Code in Electrical System E115 (Wiper Working Abnormality) Single-wiper specification User Code
Error Code
Failure Code
—
E115
DY20KA
Failure content
Failure phenomenon
Wiper Working Abnormality (Monitor Panel system)
• A W signal is not inputted at both ends of movement, when it is in motion.
Response from • Power to the windshield wiper motor is turned OFF. Monitor Panel Phenomenon occurring on machine
• The windshield wiper motor does not work.
Relative information
• Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Presumed cause and standard value in normalcy
Windshield wiper motor 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or faulty contact with connector)
W04 (female)
Between (6) and (5)
Resistance value
At upper end of operation range
Below 1 z
Outside upper end of operation range
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P01 (female) (5) and W04 (male) (6)
Resistance value
Below 1 z
Wiring harness between W04 (male) (5) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P01 3 Monitor panel defective Between (5) and grounding
20-316 (1)
Windshield wiper blade
Windshield wiper blade
Voltage
At upper end of operation range
Below 1 V
Outside upper end of operation range
20 – 30 V
PC750, 800-7
TROUBLESHOOTING
E115
Windshield Wiper Motor Electrical Circuit Diagram (Single wiper spec.)
PC750, 800-7
20-317 (1)
TROUBLESHOOTING
E116
Error Code in Electrical System E116 (Wiper Parking Abnormality) Double-wiper specification User Code
Error Code
Failure Code
—
E116
DY20MA
Failure content
Failure phenomenon
Wiper Parking Abnormality (Monitor Panel system)
• P signal on the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is retracted. Monitor Panel Phenomenon occurring on machine
• The windshield wiper cannot be retracted completely.
Relative information
• It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation range is inputted or not. (Code No.: 04502 Monitor input 3) Cause
Upper windshield wiper 1 motor defective (Internal disconnection)
Lower windshield wiper
2 motor defective Presumed cause and standard value in normalcy
(Internal disconnection)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W04 (female) Between (4) and (5)
Wiper blade
Resistance value
Retraction range
Below 1 z
Operation range
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W05 (female) Between (4) and (5)
Wiper blade
Resistance value
Retraction range
Below 1 z
Operation range
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Wiring harness between P01 (female) (12) and W04 (male) (4)
Resistance value
Below 1 z
Wiring harness between W04 (male) (5) and grounding
Resistance value
Below 1 z
Wiring harness between P01 (female) (5) and W05 (male) (4)
Resistance value
Below 1 z
Wiring harness between W05 (male) (5) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4 Monitor panel defective
P01
Upper wiper blade
Voltage
Between (12) and grounding
Retraction range
Below 1 V
Operation range
20 – 30 V
P01
Lower wiper blade
Voltage
Retraction range
Below 1 V
Operation range
20 – 30 V
Between (5) and grounding
20-318 (1)
PC750, 800-7
TROUBLESHOOTING
E116
Windshield Wiper Motor Electrical Diagram (Double wiper spec.)
PC750, 800-7
20-319 (1)
TROUBLESHOOTING
E116
Single-wiper specification User Code
Error Code
Failure Code
—
E116
DY20MA
Failure content
Failure phenomenon
Wiper Parking Abnormality (Monitor Panel system)
• P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is Monitor Panel retracted. Phenomenon occurring on machine
• The windshield wiper cannot be retracted completely.
Relative information
• It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation range is inputted or not. (Code No.: 04502 Monitor Input 3)
Presumed cause and standard value in normalcy
Cause Windshield wiper motor 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W04 (female) Between (4) and (5)
Windshield wiper blade
Resistance value
Retraction range
Below 1 z
Operation range
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P01 (female) (12) and W04 (male) (4)
Resistance value
Below 1 z
Between wiring harness W04 (male) (5) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Monitor panel defective
20-320 (1)
Standard value in normalcy and references for troubleshooting
P01
Windshield wiper blade
Voltage
Between (12) and grounding
Retraction range
Below 1V
Operation range
20 – 30 V
PC750, 800-7
TROUBLESHOOTING
E116
Windshield Wiper Motor Electrical Circuit Diagram (Single wiper spec.)
PC750, 800-7
20-321 (1)
TROUBLESHOOTING
E117
Error Code in Electrical System E117 (Eng. Controller S-NET Comm Err.) User Code
Error Code
Failure Code
—
E117
DAC0KR
Failure content
Failure phenomenon
Eng. Controller S-NET Comm Err. (Monitor Panel System)
• The monitor panel detected communication failure in the S-NET communication circuit to the engine controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%. monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy. • The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET)
Presumed cause and standard value in normalcy
Phenomenon occurring on machine
Cause
Standard value in normalcy and references for troubleshooting
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Grounding fault of wiring harness 2 (Contact with grounding circuit)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (9), (10) and E12 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between P02 (female) (9), (10) 3 harness (Contact with 24 V circuit) and E12 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) and related circuits and grounding
4
Engine controller defective
5 Monitor panel defective
20-322 (1)
Wiring harness between P02 (female) (9), (10) and E12 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21)
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. E12
Voltage
Between (21), (31) and (11)
6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
Voltage
Between (9), (10) and (20)
6–9V
PC750, 800-7
TROUBLESHOOTING
E117
Circuit diagram related to S-NET communication
PC750, 800-7
20-323 (1)
TROUBLESHOOTING
E118
Error Code in Electrical System E118 (Pump Controller S-NET Comm Err.) User Code
Error Code
Failure Code
—
E118
DAB0KR
Failure content
Failure phenomenon
Pump Controller S-NET Comm Err. (Monitor panel System)
• The monitor panel detected communication failure in the S-NET communication circuit to the pump controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%. monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy. • The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET)
Presumed cause and standard value in normalcy
Phenomenon occurring on machine
Cause
Standard value in normalcy and references for troubleshooting
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Grounding fault of wiring harness 2 (Contact with grounding circuit)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (9), (10) and E12 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between P02 (female) (9), (10) 3 harness (Contact with 24 V circuit) and E12 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) and related circuits and grounding
4
Pump controller defective
5 Monitor panel defective
20-324 (1)
Wiring harness between P02 (female) (9), (10) and E12 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21)
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C02
Voltage
Between (21) and (31)
6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
Voltage
Between (9), (10) and (20)
6–9V
PC750, 800-7
TROUBLESHOOTING
E118
Circuit diagram related to S-NET communication
PC750, 800-7
20-325 (1)
TROUBLESHOOTING
E128
Error Code in Electrical System E128 (Monitor Comm. Abnormality) User Code
Error Code
Failure Code
E0E
E128
DAF0MC
Failure content
Failure phenomenon
Monitor Comm. Abnormality (Monitor panel system)
• The monitor panel detected communication failure in the CAN communication circuit to the engine controller or pump controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%. monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information Cause
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P70 (female) (16) and E12 (female) (22) or between P70 (female) (16) and C02 (female) (22)
Resistance value
Below 1 z
Wiring harness between P70 (female) (15) and E12 (female) (32) or between P70 (female) (15) and C02 (female) (32)
Resistance value
Below 1 z
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit)
Resistance value
Above 1 Mz
Between wiring harness between P70 (female) (15) and E12 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness (Contact with 24 V circuit)
4
CAN terminal resistor defective
Monitor panel, engine 5 controller, or pump controller defective
20-326 (1)
Between wiring harness between P70 (female) (16) and E12 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding
Between wiring harness between P70 (female) (16) and E12 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding
Voltage
Below 1 V
Between wiring harness between P70 (female) (15) and E12 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. K30 (male), K31 (male)
Voltage
Between (1) and (2)
40 – 80 z
If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller may be defective. (Since trouble is in those devices, troubleshooting cannot be carried out.)
PC750, 800-7
TROUBLESHOOTING
E128
Circuit diagram related to CAN communication
PC750, 800-7
20-327 (1)
TROUBLESHOOTING
E201
Error Code in Electrical System E201 (CO Cancel Sol. S/C) User Code
Error Code
Failure Code
—
E201
DW48KB
Failure content
Failure phenomenon
CO Cancel Sol. S/C (Pump controller system)
• Abnormal current flew to the CO cancel circuit, when power was supplied to the circuit.
• Power supply to the CO cancel circuit is switched OFF. Response from • Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the controller engine starting switch is once turned OFF. Phenomenon occurring on machine
• When the boom is raised (in the heavy lift mode) and the machine travels, power is low (The pump CO function cannot be cancelled).
Relative information
• Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) Cause
Presumed cause and standard value in normalcy
CO cancel solenoid defective 1 (Internal short-circuiting or grounding fault)
Assembled-type diode 2 D03 defective (Internal short-circuiting) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V07 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (2) and grounding
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)
Resistance value (Continuitiy)
Between (1) and (5)
Min. 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (17), J06, and V07 (female) (2) or between C03 (female) (17) and D03 (female) (1) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 4
Pump controller defective
C03 Between (17) and grounding
Working mode Control lever
Voltage
At E mode + all levers in neutral
Max. 1 V
At A mode (Note)
20 – 30 V
Note: You may carry out troubleshooting while the working mode is at E-mode and the travel lever is operated or while the working mode is at E-mode and the heavy lift switch is turned ON.
20-328 (1)
PC750, 800-7
TROUBLESHOOTING
E201
Electric circuit diagram related to CO cancel solenoid
PC750, 800-7
20-329 (1)
TROUBLESHOOTING
E202
Error Code in Electrical System E202 (Travel Junction Sol. S/C) User Code
Error Code
Failure Code
—
E202
DW91KB
Failure content
Failure phenomenon
Travel Junction Sol. S/C (Pump controller system)
• Abnormal current flowed in the travel junction solenoid circuit, when power is supplied to the circuit.
• Power to the travel junction solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• When the right and left travel motors and work equipment are operated simultaneously, the machine deviates (The right and left travel circuits are not connected to each other).
Relative information
• Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) Cause
Presumed cause and standard value in normalcy
Travel junction solenoid defective 1 (Internal short-circuiting or grounding fault)
Assembled-type diode 2 D03 defective (Internal short-circuiting) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)
Resistance value (Continuitiy)
Between (3) and (7)
Above 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (7), J06, and V03 (female) (2) or between C03 (female) (7) and D03 (female) (3) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 4 Pump controller defective
C03
Travel lever and work equipment control lever
All levers in neutral Between (7) and grounding Straight travel + Operation of work equipment
20-330 (1)
Voltage Below 1 V 20 – 30 V
PC750, 800-7
TROUBLESHOOTING
E202
Electric circuit diagram related to travel junction solenoid
PC750, 800-7
20-331 (1)
TROUBLESHOOTING
E203
Error Code in Electrical System E203 (Swing Brake Sol. S/C) User Code
Error Code
Failure Code
E03
E203
DW45KB
Failure content
Failure phenomenon
Swing Brake Sol. S/C (Pump controller system)
• Abnormal current flowed in the swing holding brake solenoid circuit, when power is supplied to the circuit.
• Power to the swing holding brake solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The machine cannot swing (The swing holding brake cannot be released).
Relative information
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) • If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding brake release switch in the RELEASE position (The parking brake does not operate when the machine stops, however). Cause
Presumed cause and standard value in normalcy
Swing holding brake solenoid defective 1 (Internal short-circuiting or grounding fault)
Assembled-type diode 2 D03 defective (Internal short-circuiting)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)
Resistance value (Continuitiy)
Between (4) and (8)
Above 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (37), D01, J02, X05, J06, and V04 (female) (2) or between C03 (female) (37) and S25 (female) (8) or between C03 (female) (37) and D03 (female) (4) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. C03
Work equipment control lever
Voltage
All levers in neutral
Max. 1 V (5 sec after setting in neutral)
Work equipment or swing operated
20 – 30 V
4 Pump controller defective Between (37) and grounding
20-332 (2)
Resistance value
PC750, 800-7
TROUBLESHOOTING
E203
Electric circuit diagram related to swing holding brake
PC750, 800-7
20-333 (1)
TROUBLESHOOTING
E204
Error Code in Electrical System E204 (2-stage Relief Sol. S/C) User Code
Error Code
Failure Code
—
E204
DWK0KB
Failure content
Failure phenomenon
2-stage Relief Sol. S/C (Pump controller system)
• Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The heavy-lift function does not work. • Travel power is low (The main relief valve is not set in the HIGH PRESSURE position).
Relative information
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) Cause
Presumed cause and standard value in normalcy
2-stage relief solenoid defective 1 (Internal short-circuiting or grounding fault)
Assembled-type diode 2 D03 defective (Internal short-circuiting) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (2) and grounding
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)
Resistance value (Continuitiy)
Between (2) and (6)
Min. 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (28), J06, and V02 (female) (2) or between C03 (female) (28) and D03 (female) (2) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 4 Pump controller defective
20-334 (1)
C03
Travel control lever
Voltage
Between (28) and grounding
NEUTRAL
Max. 1 V
Travel operation
20 – 30 V
PC750, 800-7
TROUBLESHOOTING
E204
Electric circuit diagram related to 2-stage relief solenoid
PC750, 800-7
20-335 (1)
TROUBLESHOOTING
E205
Error Code in Electrical System E205 (Swing Priority Sol. S/C) User Code
Error Code
Failure Code
—
E205
DW41KB
Failure content
Failure phenomenon
Swing Priority Sol. S/C (Pump controller system)
• Abnormal current flew to the swing priority solenoid, when power was supplied to the circuit.
• Power supply to the swing priority solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• When the boom is raised and the machine is swung simultaneously in the swing priority mode, the swing speed is low (the oil flow in the swing circuit is kept low).
Relative information
• Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) Cause
Presumed cause and standard value in normalcy
Swing priority solenoid defective 1 (Internal short-circuiting or grounding fault)
Assembled-type diode 2 D04 defective (Internal short-circuiting) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V01 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (2) and grounding
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D04 (male)
Resistance value (Continuitiy)
Between (3) and (7)
Min. 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (38), J06, and V01 (female) (2) or between C03 (female) (38) and D04 (female) (3) and grounding
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
4
Pump controller defective
C03
Between (38) and grounding
20-336 (1)
Resistance value
Swing priority switch Left work equipment control lever
Voltage
OFF + NEUTRAL
Max. 1 V
Swing priority mode + Swing operation
20 – 30 V
PC750, 800-7
TROUBLESHOOTING
E205
Electric circuit diagram related to swing priority solenoid
PC750, 800-7
20-337 (1)
TROUBLESHOOTING
E206
Error Code in Electrical System E206 (Travel Speed Sol. S/C) User Code
Error Code
Failure Code
—
E206
DW43KB
Failure content
Failure phenomenon
Travel Speed Sol. S/C (Pump controller system)
• Abnormal current flew to the travel speed solenoid, when power was supplied to the circuit.
• Power supply to the travel speed solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The travel speed does not turn to Hi. (The swash plate angle of the travel motor is not minimized.)
Relative information
• The travel speed shifting solenoid is not turned ON when the engine speed is below 1,200 rpm. • Operation of the travel speed solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) Cause
Presumed cause and standard value in normalcy
Travel speed solenoid defective 1 (Internal short-circuiting or grounding fault)
Assembled-type diode 2 D04 defective (Internal short-circuiting) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V06 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (2) and grounding
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D04 (male)
Resistance value (Continuitiy)
Between (2) and (6)
Min. 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (27), J06, and V06 (female) (2) or between C03 (female) (27) and D04 (female) (2) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in high idling during the troubleshooting. 4 Pump controller defective
20-338 (1)
C03
Travel speed switch
Voltage
Between (27) and grounding
Lo
Max. 1 V
Hi
20 – 30 V
PC750, 800-7
TROUBLESHOOTING
E206
Electric circuit diagram related to travel speed solenoid
PC750, 800-7
20-339 (1)
TROUBLESHOOTING
E207
Error Code in Electrical System E207 (Flash Light Relay S/C) User Code
Error Code
Failure Code
—
E207
D163KB
Failure content
Failure phenomenon
Flash Light Relay S/C (Pump controller system)
• Abnormal current flowed in the flash light relay circuit (the primary circuit of the relay), when power is supplied to the circuit.
• The controller turns OFF the output to the coil circuit of the flash light relay. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The flash light does not flash.
Relative information
• Operation of the flash light relay circuit (the primary side of the relay) (ON or OFF) can be checked in the monitoring function. (Code No. 03701: Controller output 2) • This error code detects abnormality on the primary (coil) side of the flash light relay and cannot detect abnormality on the secondary (contact) side. Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Flash light relay defective 1 (Internal short-circuiting) R21 (male) Resistance value Grounding fault of wiring harness 2 (Contact with grounding circuit)
Between wiring harness between C03 (female) (25) and R21 (female) (1) and grounding
Resistance valve
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3
20-340 (1)
250 – 350 z
Between (1) and (2)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Pump controller defective
C03
Horn switch
Voltage
Between (25) and grounding
ON
20 – 30 V Max. 1 V (at constant cycle, 5 seconds)
OFF
Max. 1 V
PC750, 800-7
TROUBLESHOOTING
E207
Electric circuit diagram related to horn and flash light relay
PC750, 800-7
20-341 (1)
TROUBLESHOOTING
E211
Error Code in Electrical System E211 (CO Cancel Sol. Disc.) User Code
Error Code
Failure Code
—
E211
DW48KA
Failure content
Failure phenomenon
CO Cancel Sol. Disc. (Pump controller system)
• No current flows to the CO cancel solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• When the boom is raised (in the heavy lift mode) and the machine travels, power is low (The pump CO function cannot be cancelled).
Relative information
• Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E201].) Cause
Presumed cause and standard value in normalcy
CO cancel 1 solenoid defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V07 (male)
Resistance value
Between (1) and (2)
20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (17) to J06 and V07 (female) (2)
Resistance value
Max. 1 z
Wiring harness between V07 (female) (1) to J15 and grounding
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness Between wiring harness between C03 (female) (17), (Contact with 24 V circuit) J06, and V07 (female) (2) or between C03 (female) (17) Voltage Max. 1 V and D03 (female) (1) and grounding
4
20-342 (1)
Standard value in normalcy and references for troubleshooting
Pump controller defective
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (17) and grounding
20 – 60 z
PC750, 800-7
TROUBLESHOOTING
E211
Electric circuit diagram related to CO cancel solenoid
PC750, 800-7
20-343 (1)
TROUBLESHOOTING
E212
Error Code in Electrical System E212 (Travel Junction Sol. Disc.) User Code
Error Code
Failure Code
—
E212
DW91KA
Failure content
Failure phenomenon
Travel Junction Sol. Disc. (Pump controller system)
• No current flows to the travel junction solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it). controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• When the right and left travel motors and work equipment are operated simultaneously, the machine deviates (The right and left travel circuits are not connected to each other).
Relative information
• Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or OFF, refer to the troubleshooting under Error code [E202].) Cause
Presumed cause and standard value in normalcy
Travel junction solenoid 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male)
Resistance value
Between (1) and (2)
20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (7), J06, and V03 (female) (2)
Resistance value
Max. 1 z
Wiring harness between V03 (female) (1), J15, and grounding
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 3 harness (Contact with 24 V circuit) Between wiring harness between C03 (female) (7), J06, Voltage Below 1 V V03 (female) (2), and D03 (female) (3) and grounding
4 Pump controller defective
20-344 (1)
Standard value in normalcy and references for troubleshooting
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. C03 (female)
Resistance value
Between (7) and grounding
20 – 60 z
PC750, 800-7
TROUBLESHOOTING
E212
Electric circuit diagram related to travel junction solenoid
PC750, 800-7
20-345 (1)
TROUBLESHOOTING
E213
Error Code in Electrical System E213 (Swing Brake Sol. Disc.) User Code
Error Code
Failure Code
E03
E213
DW45KA
Failure content
Failure phenomenon
Swing Brake Sol. Disc. (Pump controller system)
• No current flows in the swing holding brake solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it). controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The machine cannot swing (The swing holding brake cannot be released).
Relative information
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) • If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding brake release switch in the RELEASE position (The parking brake does not operate when the machine stops, however). • Keep the swing lock switch in the OFF position and the swing holding brake release switch in the RELEASE position during troubleshooting. • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or OFF, refer to the troubleshooting under Error code [E203].) Cause
Swing holding brake 1 solenoid defective (Internal disconnection)
Assembled-type diode 2 D01 defective (Internal disconnection)
Swing lock switch Presumed cause and standard value in normalcy
3 defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male)
Resistance value
Between (1) and (2)
20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male)
Digital tester
Continuity
Between (7) and (3)
Diode mode
Continued
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. X05 (female) Between (3) and (4)
Swing lock switch
Resistance value
OFF
Max. 1 z
LOCK
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 4 (Disconnection or defective contact with connector)
Wiring harness between C03 (female) (37) and D01 (female) (7)
Resistance value
Max. 1 z
Wiring harness between D01 (female) (3), J02, and X05 (male) (3)
Resistance value
Max. 1 z
Wiring harness between X05 (male) (4), J06, and V04 (female) (2)
Resistance value
Max. 1 z
Wiring harness between V04 (female) (1), J15, and grounding
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 5 harness (Contact with 24 V circuit) Between wiring harness between C03 (female) (37) and Voltage Max. 1 V D01 (female) (7) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 6 Pump controller defective
C03 (female) Between (37) and grounding
20-346 (2)
Disconnect D01 and directly connect pins (3) and (7) on the female side.
Resistance value 20 – 60 z
PC750, 800-7
TROUBLESHOOTING
E213
Electric circuit diagram related to swing holding brake solenoid
PC750, 800-7
20-347 (1)
TROUBLESHOOTING
E214
Error Code in Electrical System E214 (2-stage Relief Sol. Disc.) User Code
Error Code
Failure Code
—
E214
DWK0KA
Failure content
Failure phenomenon
2-stage Relief Sol. Disc. (Pump controller system)
• No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The heavy-lift function does not work. • Travel power is low (The main relief valve is not set in the HIGH PRESSURE position).
Relative information
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E204].) Cause
Presumed cause and standard value in normalcy
2-stage relief solenoid 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male)
Resistance value
Between (1) and (2)
20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (28) to J06 and V02 (female) (2)
Resistance value
Max. 1 z
Wiring harness between V02 (female) (1) to J15 and grounding
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness Between wiring harness between C03 (female) (28), (Contact with 24 V circuit) J06, and V02 (female) (2) or between C03 (female) (28) Voltage Max. 1 V and D03 (female) (2) and grounding
4 Pump controller defective
20-348 (1)
Standard value in normalcy and references for troubleshooting
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (28) and grounding
20 – 60 z
PC750, 800-7
TROUBLESHOOTING
E214
Electric circuit diagram related to 2-stage relief solenoid
PC750, 800-7
20-349 (1)
TROUBLESHOOTING
E215
Error Code in Electrical System E215 (Swing Priority Sol. Disc.) User Code
Error Code
Failure Code
—
E215
DW41KA
Failure content
Failure phenomenon
Swing Priority Sol. Disc. (Pump controller system)
• No current flows to the swing priority solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• When the boom is raised and the machine is swung simultaneously in the swing priority mode, the swing speed is low (the oil flow in the swing circuit is kept low).
Relative information
• Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E205].) Cause
Presumed cause and standard value in normalcy
Swing priority solenoid 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V01 (male)
Resistance value
Between (1) and (2)
20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (38) to J06 and V01 (female) (2)
Resistance value
Max. 1 z
Wiring harness between V01 (female) (1) to J15 and grounding
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness Between wiring harness between C03 (female) (38), (Contact with 24 V circuit) J06, and V01 (female) (2) or between C03 (female) (38) Voltage Max. 1 V and D04 (female) (3) and grounding
4
20-350 (1)
Standard value in normalcy and references for troubleshooting
Pump controller defective
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. C03 (female)
Resistance value
Between (38) and grounding
20 – 60 z
PC750, 800-7
TROUBLESHOOTING
E215
Electric circuit diagram related to swing priority solenoid
PC750, 800-7
20-351 (1)
TROUBLESHOOTING
E216
Error Code in Electrical System E216 (Travel Speed Sol. Disc.) User Code
Error Code
Failure Code
—
E216
DW43KA
Failure content
Failure phenomenon
Travel Speed Sol. Disc. (Pump controller system)
• No current flows to the travel speed solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The travel speed does not shift to Hi. (The swash plate angle of the travel motor is not minimized.)
Relative information
• The travel speed shifting solenoid is not turned ON when the engine speed is below 1,200 rpm. • Operation of the travel speed solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid 1) • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E206].) Cause
Presumed cause and standard value in normalcy
Travel speed solenoid 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
V06 (male)
Resistance value
Between (1) and (2)
20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (27) to J06 and V06 (female) (2)
Resistance value
Max. 1 z
Wiring harness between V06 (female) (1) to J15 and grounding
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness Between wiring harness between C03 (female) (27), (Contact with 24 V circuit) J06, and V06 (female) (2) or between C03 (female) (27) Voltage Max. 1 V and D04 (female) (2) and grounding
4 Pump controller defective
20-352 (1)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (27) and grounding
20 – 60 z
PC750, 800-7
TROUBLESHOOTING
E216
Electric circuit diagram related to travel speed solenoid
PC750, 800-7
20-353 (1)
TROUBLESHOOTING
E217
Error Code in Electrical System E217 (Model selection Abnormality) User Code
Error Code
Failure Code
—
E217
DA2SKQ
Failure content
Failure phenomenon
Model selection Abnormality (Pump controller system)
• A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC750). Response from • Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless controller the engine starting switch is once turned OFF. Phenomenon occurring on machine
• None in particular with PC750 • 800 model
Relative information
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring function. (Code No. 00200: Controller Model Code) a Input of model selecting signals (ON or OFF) can be confirmed in the monitoring function. (Code No. 02201: Switch Input 2) Cause
Presumed cause and standard value in normalcy
Model selecting connector defective 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C09 (female)
Resistance value
Between (1) , (3), (4) and (8)
Min. 1 Mz
Between (2) and (8)
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (27) and C09 (male) (2)
Resistance value
Max. 1 z
Between wiring harness between C09 (male) (8) to J05 , J22 and grounding
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 3 (Contact with grounding circuit)
Between wiring harness between C02 (female) (37) and C09 (male) (1)
Resistance value
Min. 1 Mz
Between wiring harness between C02 (female) (17) and C09 (male) (3) and grounding
Resistance value
Min. 1 Mz
Between wiring harness between C02 (female) (7) and C09 (male) (4) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Pump controller defective
20-354 (1)
C02
Voltage
Between (7), (17), (37) and grounding
20 – 30 V
Between (27) and grounding
Max. 1 V
PC750, 800-7
TROUBLESHOOTING
E217
Electric circuit diagram related to model selection connector (for pump controller)
PC750, 800-7
20-355 (1)
TROUBLESHOOTING
E218
Error Code in Electrical System E218 (S-Net Comm. Disc.) User Code
Error Code
Failure Code
E0E
E218
DA2SKA
Failure content
Failure phenomenon
S-Net Comm. Disc. (Pump controller system)
• The pump controller detected communication failure in the S-NET communication circuit to the monitor panel or engine controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET) Cause
Standard value in normalcy and references for troubleshooting
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Presumed cause and standard value in normalcy
Grounding fault of wiring harness 2 (Contact with grounding circuit)
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (9), (10) and E12 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) or between P02 (female) (9), (10) and related circuits and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between P02 (female) (9), (10) 3 harness (Contact with 24 V circuit) and E12 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) or between P02 (female) (9), (10) and related circuits and grounding
4 Monitor panel defective
5
Engine controller defective
6 Pump controller defective
20-356 (1)
Wiring harness between P02 (female) (9), (10) and E12 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21)
Voltage
Max. 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
Voltage
Between (9), (10) and (20)
6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. E12
Voltage
Between (21), (31) and (11)
6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C02
Voltage
Between (21) and (31)
6–9V
PC750, 800-7
TROUBLESHOOTING
E218
Electrical Circuit Diagram for S-NET Communication
PC750, 800-7
20-357 (1)
TROUBLESHOOTING
E221
Error Code in Electrical System E221 (Travel Alarm S/C) User Code
Error Code
Failure Code
—
E221
DV20KB
Failure content
Failure phenomenon
Travel Alarm S/C (Pump controller system)
• Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit.
• Power to the travel alarm circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The travel alarm does not sound.
Relative information
• Operation of the travel alarm (ON or OFF) can be checked in the monitoring function. (Code No. 03701: Controller output 2) Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 1
Travel alarm defective (Internal defect)
F01 (female) Between (1) and (2)
Voltage
Neutral
Max. 1 V
Operated
20 – 30 V
If the above voltage is normal but the travel alarm does not operate, the travel alarm is defective. Grounding fault of wiring harness 2 (Contact with grounding circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (8) and F01 (female) (1) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 3 Pump controller defective
C03 Between (8) and grounding
20-358 (1)
Travel lever
Travel lever
Voltage
Neutral
Max. 1 V
Operated
20 – 30 V
PC750, 800-7
TROUBLESHOOTING
E221
Circuit diagram related to travel alarm
PC750, 800-7
20-359 (1)
TROUBLESHOOTING
E224
Error Code in Electrical System E224 (F Pump P. Sensor Abnormality) User Code
Error Code
Failure Code
—
E224
DHPAMA
Failure content
Failure phenomenon
F Pump P. Sensor Abnormality (Pump controller system)
• Signal voltage from the front pump pressure sensor is below 0.3 V or above 4.42 V.
Response from • When the failure cause disappears of itself, the machine operation returns to normalcy. controller Phenomenon occurring on machine
• The front pump pressure cannot be monitored (Special function of monitor panel).
Relative information
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. • Input from the front pump pressure sensor (pressure) can be checked in the monitoring function. (Code No. 01100: Front pump pressure) Cause
1
Sensor power supply system defective
Standard value in normalcy and references for troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting.
Front pump pressure 2 sensor defective (Internal defect)
P30
Voltage
Between (B) and (A)
Power supply
4.5 – 5.5 V
Between (C) and (A)
Signal
0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge.
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Wiring harness between C01 (female) (22), J21, and P30 (female) (B)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (10), J08, and P30 (female) (A)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (8) and P30 (female) (C)
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (8) and P30 (female) (C) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between C01 (female) (22), 5 harness J21, and P30 (female) (B) and grounding (Contact with 24 V circuit) Between wiring harness between C01 (female) (8) and P30 (female) (C) and grounding
Voltage
Max. 1 V
Voltage
Max. 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 6 Pump controller defective
20-360 (1)
C01
Voltage
Between (22) and (10)
4.5 – 5.5 V
Between (8) and (10)
0.5 – 4.5 V
PC750, 800-7
TROUBLESHOOTING
E224
Circuit diagram related to front pump pressure sensor
PC750, 800-7
20-361 (1)
TROUBLESHOOTING
E225
Error Code in Electrical System E225 (R Pump P. Sensor Abnormality) User Code
Error Code
Failure Code
—
E225
DHPBMA
Failure content
Failure phenomenon
R Pump P. Sensor Abnormality (Pump controller system)
• Signal voltage from the rear pump pressure sensor is below 0.3 V or above 4.42 V.
Response from • When the failure cause disappears of itself, the machine operation returns to normalcy. controller Phenomenon occurring on machine
• The rear pump pressure cannot be monitored (Special function of monitor panel).
Relative information
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. • Input from the rear pump pressure sensor (pressure) can be checked in the monitoring function. (Code No. 01101: Rear pump pressure) Cause
1
Sensor power supply system defective
Standard value in normalcy and references for troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting.
Rear pump pressure 2 sensor defective (Internal defect)
P31
Voltage
Between (B) and (A)
Power supply
4.5 – 5.5 V
Between (C) and (A)
Signal
0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge.
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Wiring harness between C01 (female) (22), J21, and P31 (female) (B)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (10), J08, and P31 (female) (A)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (2) and P31 (female) (C)
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (2) and P31 (female) (C) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between C01 (female) (22), 5 harness J21, and P31 (female) (B) and grounding (Contact with 24 V circuit) Between wiring harness between C01 (female) (2) and P31 (female) (C) and grounding
Voltage
Max. 1 V
Voltage
Max. 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 6 Pump controller defective
20-362 (1)
C01
Voltage
Between (22) and (10)
4.5 – 5.5 V
Between (2) and (10)
0.5 – 4.5 V
PC750, 800-7
TROUBLESHOOTING
E225
Circuit diagram related to rear pump pressure sensor
PC750, 800-7
20-363 (1)
TROUBLESHOOTING
E226
Error Code in Electrical System E226 (Press. Sensor Power Abnormality) User Code
Error Code
Failure Code
—
E226
DA25KP
Failure content
Failure phenomenon
Press. Sensor Power Abnormality (Pump controller system)
• Abnormal current flowed in the pressure sensor power supply (5 V) circuit.
• Power to the power supply (5 V) circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The pressure sensor signal is not input normally. • The error code of abnormality in the pressure sensor is displayed, too.
Relative information Cause
Standard value in normalcy and references for troubleshooting a Disconnect the connector when the engine starting switch is in OFF, and hold it in the ON position during the troubleshooting.
Presumed cause and standard value in normalcy
Pressure sensor 1 defective (Internal short-circuiting)
Front pump pressure sensor
Connector P30
Rear pump pressure sensor
Connector P31
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit)
3 Pump controller defective
20-364 (1)
Disconnect the parts shown at right in order. If the error code goes off when one of those parts is disconnected, that part is defective.
Between wiring harness between C01 (female) (22), J21, and P30 (female) (B) and grounding [Front pump pressure sensor system]
Resistance value
Min. 1 Mz
Between wiring harness between C01 (female) (22), J21, and P31 (female) (B) and grounding [Rear pump pressure sensor system]
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C01
Voltage
Between (22) and (10)
4.5 – 5.5 V
PC750, 800-7
TROUBLESHOOTING
E226
Circuit diagram related to pressure sensor power supply
PC750, 800-7
20-365 (1)
TROUBLESHOOTING
E227
Error Code in Electrical System E227 (Engine Speed Sensor Abnormality) User Code
Error Code
Failure Code
—
E227
DLE2MA
Failure content
Failure phenomenon
Engine Speed Sensor Abnormality (Pump controller system)
• Normal pulse signal is not input to the signal circuit of the engine speed sensor.
Response from • Control is carried out as in the E-mode. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• Power is a little low (Engine speed cannot be sensed). • The monitor panel cannot monitor the engine speed (pump controller system).
Relative information
• Input from the engine speed sensor (rpm) can be checked in the monitoring function. (Code No. 01006: Engine speed) Cause
Presumed cause and standard value in normalcy
Engine speed sensor defective 1 (Internal short-circuiting or disconnection) 2
Engine speed sensor adjustment defective
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. ENE (male)
Resistance value
Between (1) and (2)
300 – 1,000 z
Between (1) and grounding
Min. 1 Mz
Refer to TESTING AND ADJUSTING, Adjusting engine speed sensor. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (40) and ENE (female) (1)
Resistance value
Max. 1 z
Wiring harness between C02 (female) (39) and ENE (female) (2)
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness (Contact with 24 V circuit) Wiring harness between C02 (female) (40) and ENE Voltage Max. 1 V (female) (1) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5 Pump controller defective
20-366 (1)
C02 (female)
Resistance value
Between (40) and (39)
300 – 1,000 z
Between (39), (40) and grounding
Min. 1 Mz
PC750, 800-7
TROUBLESHOOTING
E227
Electric circuit diagram related to engine speed sensor
PC750, 800-7
20-367 (1)
TROUBLESHOOTING
E232
Error Code in Electrical System E232 (TVC Sol. S/C) User Code
Error Code
Failure Code
E02
E232
DXA0KB
Failure content
Failure phenomenon
TVC Sol. S/C (Pump controller system)
• Abnormal current flowed in the TVC solenoid circuit.
• Power to the TVC solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• If the pump load increases, the engine speed lowers extremely and the engine may stall. (The pump absorption torque cannot be controlled.)
Relative information
• Output to the TVC solenoid (current) can be checked in the monitoring function. (Code No. 01300: TVC solenoid current) • If the solenoid and wiring harness are normal, the machine can be operated with the output equivalent to the E-mode by setting the emergency pump drive switch in the EMERGENCY position (Error code [E233] is displayed at this time, but it does not indicate a failure). • Keep the emergency pump drive switch in the normal position during troubleshooting. Cause
Presumed cause and standard value in normalcy
TVC solenoid defective 1 (Internal short-circuiting or grounding fault)
Emergency pump drive switch defective 2 (Internal short-circuiting or grounding fault)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C13 (male)
Resistance value
Between (1) and (2)
10 – 22 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S25 (male) Between (3) and (4) Between (3) and grounding
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Emergency pump drive switch
Resistance value Above 1 Mz
NORML position
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (16) and S25 (female) (3) and grounding
Resistance value
Above 1 Mz
Between wiring harness between S25 (female) (2) and C13 (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Pump controller defective
20-368 (1)
C03 (female)
Resistance value
Between (16) and (3)
10 – 22 z
Between (16) and grounding
Above 1 Mz
PC750, 800-7
TROUBLESHOOTING
E232
Electric circuit diagram related to TVC solenoid
PC750, 800-7
20-369 (1)
TROUBLESHOOTING
E233
Error Code in Electrical System E233 (TVC Sol. Disc.) User Code
Error Code
Failure Code
E02
E233
DXA0KA
Failure content
Failure phenomenon
TVC Sol. Disc. (Pump controller system)
• No current flows in the TVC solenoid circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it). controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• If the pump load increases, the engine speed lowers extremely and the engine may stall. (The pump absorption torque cannot be controlled.)
Relative information
• Output to the TVC solenoid (current) can be checked in the monitoring function. (Code No. 01300: TVC solenoid current) • If the solenoid and wiring harness are normal, the machine can be operated with the output equivalent to the E-mode by setting the emergency pump drive switch in the EMERGENCY position. Cause
1
TVC solenoid defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C13 (male)
Resistance value
Between (1) and (2)
10 – 22 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Presumed cause and standard value in normalcy
Emergency pump drive 2 switch defective (Internal disconnection)
Emergency pump drive switch
Resistance value
NORML position
Below 1 z
EMERGENCY position
Above 1 Mz
NORML position
Below 1 z
EMERGENCY position
Above 1 Mz
S25 (male) Between (2) and (3) Between (5) and (6)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Wiring harness between C03 (female) (16) and S25 (female) (3)
Resistance value
Below 1 z
Wiring harness between S25 (female) (2) and C13 (female) (1)
Resistance value
Below 1 z
Wiring harness between C03 (female) (3) and S25 (female) (6)
Resistance value
Below 1 z
Wiring harness between S25 (female) (5) and C13 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between C03 (female) (16) and 4 harness S25 (female) (3) and grounding (Contact with 24 V circuit) Between wiring harness between S25 (female) (2) and C13 (female) (1) and grounding
5 Pump controller defective
20-370 (1)
Voltage
Below 1 V
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (16) and (3)
10 – 22 z
PC750, 800-7
TROUBLESHOOTING
E233
Electric circuit diagram related to TVC solenoid
PC750, 800-7
20-371 (1)
TROUBLESHOOTING
E257
Error Code in Electrical System E257 (Pump Comm. Abnormality) User Code
Error Code
Failure Code
E0E
E257
DA2RMC
Failure content
Failure phenomenon
Pump Comm. Abnormality (Pump controller system)
• The pump controller detected communication failure in the CAN communication circuit to the monitor panel or engine controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information Cause
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P70 (female) (16) and E12 (female) (22) or between P70 (female) (16) and C02 (female) (22)
Resistance value
Below 1 z
Wiring harness between P70 (female) (15) and E12 (female) (32) or between P70 (female) (15) and C02 (female) (32)
Resistance value
Below 1 z
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit)
Between wiring harness between P70 (female) (16) and E12 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding
Resistance value
Above 1 Mz
Between wiring harness between P70 (female) (15) and E12 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness (Contact with 24 V circuit)
4
CAN terminal resistor defective
Between wiring harness between P70 (female) (16) and E12 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding
Voltage
Below 1 V
Between wiring harness between P70 (female) (15) and E12 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. K30 (male), K31 (male)
Resistance value
Between (1) and (2)
40 – 80 z
Monitor panel, If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller 5 engine controller, or may be defective. (Since trouble is in those devices, troubleshooting cannot be carpump controller defective ried out.)
20-372 (1)
PC750, 800-7
TROUBLESHOOTING
E257
Circuit diagram related to CAN communication
PC750, 800-7
20-373 (1)
TROUBLESHOOTING
E302
Error Code in Electrical System E302 (Step Light Relay S/C) User Code
Error Code
Failure Code
—
E302
D195KB
Failure content
Failure phenomenon
Step Light Relay S/C (Pump controller system)
• Abnormal current flowed in the step light relay circuit (the primary circuit of the relay), when power is supplied to the circuit.
• Power to the step light relay circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• Step light does not light up.
Relative information
• Operation of the step light relay circuit (the primary side of the relay) (ON or OFF) can be checked in the monitoring function. (Code No. 03701: Controller output 2) • This error code detects abnormality on the primary (coil) side of the step light relay and cannot detect abnormality on the secondary (contact) side. Cause
Presumed cause and standard value in normalcy
1
Step light relay defective (Internal short-circuiting)
Grounding fault of wiring harness 2 (Contact with grounding circuit)
R15 (male)
Resistance value
Between (1) and (2)
250 – 350 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (15) and R15 (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 3 Pump controller defective
20-374 (1)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
C03
Step light switch
Voltage
Between (15) and grounding
ON
20 – 30 V (Kept for 60 sec)
OFF
Below 1 V
PC750, 800-7
TROUBLESHOOTING
E302
Electric circuit diagram related to step light
PC750, 800-7
20-375 (1)
TROUBLESHOOTING
E304
Error Code in Electrical System E304 (Step Light Power Hold Relay S/C) User Code
Error Code
Failure Code
—
E304
D194KB
Failure content
Failure phenomenon
Step Light Power Hold Relay S/C (Pump controller system)
• Abnormal current flowed in the step light power hold relay circuit (the primary circuit of the relay), when power is supplied to the circuit.
• Power to the step light power hold relay circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• Step light does not light up.
Relative information
• Operation of the step light power hold relay circuit (the primary side of the relay) (ON or OFF) can be checked in the monitoring function. (Code No. 03701: Controller output 2) • This error code detects abnormality on the primary (coil) side of the step light power hold relay and cannot detect abnormality on the secondary (contact) side.
Presumed cause and standard value in normalcy
Cause Step light power hold 1 relay defective (Internal short-circuiting) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R15 (male)
Resistance value
Between (1) and (2)
250 – 350 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (5), D02, and R14 (female) (1) or between C03 (female) (5) and D04 (female) (4) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 3 Pump controller defective
C03 Between (5) and grounding
20-376 (1)
Resistance value
Step light switch
Voltage
ON
20 – 30 V (Kept for 60 sec)
OFF
Below 1 V
PC750, 800-7
TROUBLESHOOTING
E304
Electric circuit diagram related to step light
PC750, 800-7
20-377 (1)
TROUBLESHOOTING
E315
Error Code in Electrical System E315 (Battery Relay Drive S/C) User Code
Error Code
Failure Code
—
E315
D110KB
Failure content
Failure phenomenon
Battery Relay Drive S/C (Pump controller system)
• When a signal is output to the battery relay drive circuit, abnormal current flowed.
Response from • The controller turns OFF the output to the battery relay drive circuit. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• There may be a trouble in writing data into the ROM (non-volatile memory) of each controller.
Relative information
• Operation of the battery relay (ON or OFF) can be checked in the monitoring function. (Code No. 03700: Controller output 1)
Presumed cause and standard value in normalcy
Cause Battery relay defective 1 (Internal short-circuiting or grounding fault)
Grounding fault of wiring harness 2 (Contact with grounding circuit)
3
20-378 (1)
Pump controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Battery relay (Unit)
Resistance value
Between BR and E
Approx. 100 z
Between BR and grounding
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (4), D01, J01, battery relay terminal BR or between C03 (female) (4) and starting switch terminal B or between C03 (female) (4) and D01 (female) (2) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C03 (female)
Starting switch
Voltage
Between (4) and grounding
ON o OFF
20 – 30 V (For 0.5 sec)
PC750, 800-7
TROUBLESHOOTING
E315
Circuit diagram related to battery relay drive
PC750, 800-7
20-379 (1)
TROUBLESHOOTING
E91B
Error Code in Electrical System E91B (Engine Ne sensor problem) User Code
Error Code
Failure Code
E11
E91B
DLE3LC
Failure content
Failure phenomenon
Engine Ne sensor problem (Engine controller system)
• Cranking angle cannot be judged from the engine Ne speed sensor signal.
Response from • The machine is driven with limited output. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the engine Ne speed sensor (rpm) can be checked in the monitoring function. (Code No. 01002: Engine speed) • Special adapter (799-601-9410) is necessary for troubleshooting for the engine Ne speed sensor. Cause
Presumed cause and standard value in normalcy
Engine Ne speed sensor defective 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. NE (male)
Resistance value
Between (1) and (2)
85 – 210 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E12 (female) (36) and NE (female) (2)
Resistance value
Below 1 z
Wiring harness between E12 (female) (26) and NE (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (36) and NE (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E12 (female) (26) and NE (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
Engine controller defective
E12 (female)
Resistance value
Between (36) and (26)
85 – 210 z
Between (36), (26) and grounding
Above 1 Mz
Circuit diagram related to engine Ne speed sensor
20-380 (2)
PC750, 800-7
TROUBLESHOOTING
E91C
Error Code in Electrical System E91C (Engine G sensor problem) User Code
Error Code
Failure Code
E11
E91C
DLH1LC
Failure content
Failure phenomenon
Engine G sensor problem (Engine controller system)
• Cylinder cannot be judged from the engine G speed sensor signal.
• The machine is driven with limited output. Response from • Control is carried out with the Ne speed sensor signal. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Special adapter (799-601-9410) is necessary for troubleshooting for the engine G speed sensor. Cause
Presumed cause and standard value in normalcy
Engine G speed sensor defective (Internal dis1 connection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. G (male)
Resistance value
Between (1) and (2)
1.4 k – 3.5 kz
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E12 (female) (35) and G (female) (2)
Resistance value
Below 1 z
Wiring harness between E12 (female) (25) and G (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (35) and G (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E12 (female) (25) and G (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
Engine controller defective
E12 (female)
Resistance value
Between (35) and (25)
1.4 k – 3.5 kz
Between (35), (25) and grounding
Above 1 Mz
Circuit diagram related to engine G speed sensor
PC750, 800-7
20-381 (2)
TROUBLESHOOTING
E920
Error Code in Electrical System E920 (Engine type selection error) User Code
Error Code
Failure Code
E11
E920
DB29KQ
Failure content
Failure phenomenon
Engine type selection error (Engine controller system)
• The model selection signal directly taken by the engine controller does not conform to the model in the controller or it is not confirmed.
• Control is carried out with the default model (PC750). Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• The model name (figure) recognized by the controller can be checked in the monitoring function. (Code No. 00201: Controller model code) • Input of the model selection signal (ON or OFF) can be checked in the monitoring function. (Code No. 17400: Engine controller input state) Cause
Presumed cause and standard value in normalcy
Model selection connector defective 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E09 (female)
Resistance value
Between (1), (3) and (8)
Above 1 Mz
Between (2) and (8)
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E11 (female) (23) and E09 (male) (2)
Resistance value
Below 1 z
Wiring harness between E12 (female) (1) and E09 (male) (8)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E11 (female) (3) and E09 (male) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E11 (female) (17) and E09 (male) (3) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4
20-382 (1)
Engine controller defective
E11, E12
Voltage
Between E11 (3), (17) and E12 (1)
20 – 30 V
Between E11 (23) and E12 (1)
Below 1 V
PC750, 800-7
TROUBLESHOOTING
E920
Circuit diagram related to model selection connector (for engine controller)
PC750, 800-7
20-383 (1)
TROUBLESHOOTING
E921
Error Code in Electrical System E921 (Engine type mismatch) User Code
Error Code
Failure Code
E11
E921
DB20KQ
Failure content
Failure phenomenon
Engine type mismatch (Engine controller system)
• The model information taken by the engine controller through the model selection connector does not conform to the model information taken from the pump controller by communication.
• The normal operation is continued. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• The model name (figure) recognized by the engine controller can be checked in the monitoring function. (Code No. 00201: Controller model code) • The model name (figure) recognized by the pump controller can be checked in the monitoring function. (Code No. 00200: Controller model code)
Presumed cause and standard value in normalcy
Phenomenon occurring on machine
Cause 1
Model selection connector system defective
If error code [E920] is displayed, carry out troubleshooting for it.
2
Engine controller defective
Engine controller may be defective. (Since trouble is in the controller, troubleshooting cannot be carried out.)
3 Pump controller defective
20-384 (1)
Standard value in normalcy and references for troubleshooting
Pump controller may be defective. (Since trouble is in the controller, troubleshooting cannot be carried out.)
PC750, 800-7
TROUBLESHOOTING
E931
Error Code in Electrical System E931 (Fuel dial sys. error) User Code
Error Code
Failure Code
E14
E931
DK10KX
Failure content
Failure phenomenon
Fuel dial sys. error (Engine controller system)
• The signal voltage from the fuel control dial is below 0.3 V or above 4.5 V.
• If the abnormality is detected before the engine is started, the fuel control dial signal is kept at 0% or 100% after the engine is started. Response from • If the abnormality is detected while the engine is running, the fuel control dial signal just before the controller abnormality is detected is kept. • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The engine speed cannot be controlled.
Relative information
• Input from the fuel control dial (voltage) can be checked in the monitoring function. (Code No. 03000: Fuel control dial voltage) Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting.
Fuel control dial defective 1 (Internal disconnection or short-circuiting)
E06 (male)
Resistance value
Between (1) and (3)
4.0 – 6.0 kz
Between (1) and (2)
0.25 – 7.0 kz
Between (3) and (2)
0.25 – 7.0 kz
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Wiring harness between E12 (female) (19) and E06 (female) (1)
Resistance value
Below 1 z
Wiring harness between E12 (female) (10) and E06 (female) (2)
Resistance value
Below 1 z
Wiring harness between E12 (female) (29), J09, and E06 (female) (3)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (19) and E06 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E12 (female) (10) and E06 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between E12 (female) (19) and 4 harness E06 (female) (1) and grounding (Contact with 24 V circuit) Between wiring harness between E12 (female) (10) and E06 (female) (2) and grounding
Voltage
Below 1 V
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 5
20-386 (1)
Engine controller defective
E12
Voltage
Between (19) and (29)
4.6 – 5.4 V
Between (10) and (29)
0.3 – 4.5 V
PC750, 800-7
TROUBLESHOOTING
E931
Circuit diagram related to fuel control dial
PC750, 800-7
20-387 (1)
TROUBLESHOOTING
E934
Error Code in Electrical System E934 (Engine coolant sensor Hi error) User Code
Error Code
Failure Code
E15
E934
DGE2KX
Failure content
Failure phenomenon
Engine coolant sensor Hi error (Engine controller system)
• The signal voltage from the engine water high temperature sensor is below 0.5 V or above 4.5 V.
Response from • The signal of the engine water high temperature sensor is kept at 90°C. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.
Relative information
• Input from the engine water high temperature sensor (voltage and water temperature) can be checked in the monitoring function. (Code No. 04106: Engine water temperature sensor Hi, 04102: Engine water temperature (High temperature)) Cause
Presumed cause and standard value in normalcy
Engine water high temperature sensor defective 1 (Internal disconnection or short circuit)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. TWH (male)
Resistance value
Between (1) and (2)
3.5 k – 90 kz
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E12 (female) (27) and TWH (female) (1)
Resistance value
Below 1 z
Wiring harness between E12 (female) (39), J09, and TWH (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (27) and TWH (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
20-388 (1)
Engine controller defective
E12
Resistance value
Between (27) and (39)
3.5 k – 90 kz
Between (27), (39) and grounding
Above 1 Mz
PC750, 800-7
TROUBLESHOOTING
E934
Circuit diagram related to engine water temperature sensor (for low temperature and high temperature)
PC750, 800-7
20-389 (1)
TROUBLESHOOTING
E936
Error Code in Electrical System E936 (Engine oil press. sw. error) User Code
Error Code
Failure Code
E15
E936
DDE2L6
Failure content
Failure phenomenon
Engine oil press. sw. error (Engine controller system)
• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of the high-pressure switch is opened (disconnected from grounding) while the engine is running. • The signal circuit of the low-pressure switch is opened (disconnected from grounding) while the engine is stopped (the starting signal is OFF). • The signal circuit of the high-pressure switch is opened (disconnected from grounding) while the engine is stopped (the starting signal is OFF).
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.
Relative information
• Input from the engine oil pressure switch (Lo or Hi) (ON or OFF) can be checked in the monitoring function. (Code No. 17400: Engine controller input) Cause
Engine low-oil pressure switch defective 1 (Internal disconnection or short-circuiting)
Presumed cause and standard value in normalcy
Engine high-oil pressure switch defective 2 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position and start the engine during the troubleshooting. PSL
Engine
Resistance value
Between terminal and grounding
Stopped
Below 1 z
Low idling
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position and start the engine during the troubleshooting. PSH Between terminal and grounding
Engine
Resistance value
Stopped
Below 1 z
Running at 1,300 rpm or higher
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E11 (female) (21) and PSL
Resistance value
Below 1 z
Wiring harness between E11 (female) (15) and PSH
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E11 (female) (21) and PSL and grounding
Resistance value
Above 1 Mz
Between wiring harness between E11 (female) (15) and PSH and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position and start the engine during the troubleshooting.
5
Engine controller defective
E11
Engine
Voltage
Between (21) and grounding (Low-pressure switch signal)
Stopped
Below 1 V
Low idling
20 – 30 V
Stopped
Below 1 V
Running at 1,300 rpm or higher
20 – 30 V
Between (15) and grounding (High-pressure switch signal)
Carry out troubleshooting while the engine is running 15 seconds after the engine is started.
20-390 (1)
PC750, 800-7
TROUBLESHOOTING
E936
Circuit diagram related to engine water temperature sensor (for low pressure and high pressure)
PC750, 800-7
20-391 (1)
TROUBLESHOOTING
E93C
Error Code in Electrical System E93C (Engine boost sensor error) User Code
Error Code
Failure Code
E11
E93C
DH30KX
Failure content
Failure phenomenon
Engine boost sensor error (Engine controller system)
• The signal voltage from the boost pressure sensor is below 0.3 V or above 4.7 V.
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the boost pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36501: Boost pressure sensor voltage, 36500: Boost pressure) • Special adapter (799-601-9420) is necessary for troubleshooting for the engine boost pressure sensor. Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting.
Boost pressure sensor 1 defective (Internal defect)
PIM
Voltage
Between (3) and (1)
Power supply
4.6 – 5.4 V
Between (2) and (1)
Signal
0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge.
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Wiring harness between E12 (female) (9), J20, and PIM (female) (3)
Resistance value
Below 1 z
Wiring harness between E12 (female) (39), J09, and PIM (female) (1)
Resistance value
Below 1 z
Wiring harness between E12 (female) (20) and PIM (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (9), J20, and PIM (female) (3) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E12 (female) (20) and PIM (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between E12 (female) (9), J20, 4 harness and PIM (female) (3) and grounding (Contact with 24 V circuit) Between wiring harness between E12 (female) (20) and PIM (female) (2) and grounding
Voltage
Below 1 V
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 5
20-392 (1)
Engine controller defective
E12
Voltage
Between (9) and (39)
4.6 – 5.4 V
Between (20) and (39)
0.5 – 4.5 V
PC750, 800-7
TROUBLESHOOTING
E93C
Circuit diagram related to boost pressure sensor
PC750, 800-7
20-393 (1)
TROUBLESHOOTING
E93D
Error Code in Electrical System E93D (Engine fuel temp. sensor error) User Code
Error Code
Failure Code
E15
E93D
DGE4KX
Failure content
Failure phenomenon
Engine fuel temp. sensor error (Engine controller system)
• The signal voltage from the fuel temperature sensor is above 4.5 V.
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.
Relative information
• Input from the fuel temperature sensor (voltage) can be checked in the monitoring function. (Code No. 14201: Fuel temperature sensor voltage) Cause
Presumed cause and standard value in normalcy
Fuel temperature sensor defective 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. THL (male)
Resistance value
Between (A) and (B)
0.3 k – 9 kz
Between (A), (B) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E12 (female) (17) and THL (female) (A)
Resistance value
Below 1 z
Wiring harness between E12 (female) (29) and THL (female) (B)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (17) and THL (female) (A) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
20-394 (1)
Engine controller defective
E12
Resistance value
Between (17) and (29)
0.3 k – 9 kz
Between (17), (29) and grounding
Above 1 Mz
PC750, 800-7
TROUBLESHOOTING
E93D
Circuit diagram related to fuel temperature sensor
PC750, 800-7
20-395 (1)
TROUBLESHOOTING
E953
Error Code in Electrical System E953 (Engine Comm. Abnormality) User Code
Error Code
Failure Code
E0E
E953
DB2RMC
Failure content
Failure phenomenon
Engine Comm. Abnormality (Engine controller system)
• The engine controller detected communication failure in the CAN communication circuit to the monitor panel or pump controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information Cause
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P70 (female) (16) and E12 (female) (22) or between P70 (female) (16) and C02 (female) (22)
Resistance value
Below 1 z
Wiring harness between P70 (female) (15) and E12 (female) (32) or between P70 (female) (15) and C02 (female) (32)
Resistance value
Below 1 z
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit)
Between wiring harness between P70 (female) (16) and E12 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding
Resistance value
Above 1 Mz
Between wiring harness between P70 (female) (15) and E12 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness (Contact with 24 V circuit)
4
CAN terminal resistor defective
Between wiring harness between P70 (female) (16) and E12 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding
Voltage
Below 1 V
Between wiring harness between P70 (female) (15) and E12 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. K30 (male), K31 (male)
Resistance value
Between (1) and (2)
40 – 80 z
Monitor panel, If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller 5 engine controller, or may be defective. (Since trouble is in those devices, troubleshooting cannot be carpump controller defective ried out.)
20-396 (1)
PC750, 800-7
TROUBLESHOOTING
E953
Circuit diagram related to CAN communication
PC750, 800-7
20-397 (1)
TROUBLESHOOTING
E954
Error Code in Electrical System E954 (Short engine starter sw.) User Code
Error Code
Failure Code
—
E954
DD11KB
Failure content
Failure phenomenon
Short engine starter sw. (Engine controller system)
• Starting switch signal C (starting signal) is detected while the engine is running (at 500 rpm or higher).
Response from • Starting switch signal is recognized to be OFF. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The machine operates normally.
Relative information
• Input of starting switch signal C (ON or OFF) can be checked in the monitoring function. (Code No. 17400: Engine controller input) Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF and ON positions during the troubleshooting.
Presumed cause and standard value in normalcy
1
Starting switch Between terminal B and terminal C
Resistance value OFF
Above 1 Mz
START
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between starting switch termiShort-circuiting of wiring nal C, J01, and E11 (female) (20) or between starting 2 harness switch terminal C and C01 (female) (17) or between (Contact with 24 V circuit) starting switch terminal C and P01 (female) (4) or between starting switch terminal C and R11 (female) (5), or between starting switch terminal C and related circuits and grounding
4
20-398 (1)
Starting switch defective (Internal short-circuiting)
Engine controller defective
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. E11
Starting switch
Voltage
Between (20) and grounding
ON (Engine is running)
Below 1 V
PC750, 800-7
TROUBLESHOOTING
E954
Circuit diagram related to preheating, starting and charging of engine
PC750, 800-7
20-399 (1)
TROUBLESHOOTING
E955
Error Code in Electrical System E955 (Engine S-NET error) User Code
Error Code
Failure Code
E0E
E955
DB2SMC
Failure content
Failure phenomenon
Engine S-NET error (Engine controller system)
• The engine controller detected communication failure in the S-NET communication circuit to the monitor panel or pump controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET) Cause
Standard value in normalcy and references for troubleshooting
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Presumed cause and standard value in normalcy
Grounding fault of wiring harness 2 (Contact with grounding circuit)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (9), (10) and E12 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) or between P02 (female) (9), (10) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between P02 (female) (9), (10) 3 harness (Contact with 24 V circuit) and E12 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) or between P02 (female) (9), (10) and related circuits and grounding
4 Monitor panel defective
5
Engine controller defective
6 Pump controller defective
20-400 (1)
Wiring harness between P02 (female) (9), (10) and E12 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21)
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
Voltage
Between (9), (10) and (20)
6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. E12
Voltage
Between (21), (31) and (11)
6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C02
Voltage
Between (21) and (31)
6–9V
PC750, 800-7
TROUBLESHOOTING
E955
Circuit diagram related to S-NET communication
PC750, 800-7
20-401 (1)
TROUBLESHOOTING
E956
Error Code in Electrical System E956 (Engine power failure (1)) User Code
Error Code
Failure Code
E10
E956
DB22KK
Failure content
Failure phenomenon
Engine power failure (1) (Engine controller system)
• When the starting switch is turned ON, the source voltage of the controller is below 10 V.
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The engine stalls. • The engine cannot be started.
Relative information Cause Circuit breaker 7 1 defective
Standard value in normalcy and references for troubleshooting If circuit breaker is turned OFF, the circuit probably has grounding fault, etc. (See cause 4.)
Engine controller power a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. supply relay defective 2 (Internal disconnection or Replace the power supply relay with another one. If the condition R22 short-circuiting) becomes normal, the relay is defective.
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Wiring harness between E13 (female) (1), (2), (21) and R22 (female) (5)
Resistance value
Below 1 z
Wiring harness between R22 (female) (3) and B27
Resistance value
Below 1 z
Wiring harness between B17 and battery relay B terminal
Resistance value
Below 1 z
Wiring harness between R22 (female) (1) and J02 (male) (1)
Resistance value
Below 1 z
Wiring harness between R22 (female) (2) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 4 (Contact with grounding circuit)
Between wiring harness between E13 (female) (1), (2), (21) and R22 (female) (5) and grounding
Resistance value
Above 1 Mz
Between wiring harness between R22 (female) (3) and B27
Resistance value
Above 1 Mz
Between wiring harness between R22 (female) (1) and J02 (male) (1) or between R22 (female) (1) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF and ON positions during the troubleshooting. 5
20-402 (1)
Engine controller defective
E13
Starting switch
Voltage
Between (1), (2), (21) and (11), (31), (32)
OFF
Below 1 V
ON
20 – 30 V
PC750, 800-7
TROUBLESHOOTING
E956
Circuit diagram related to engine controller power supply
PC750, 800-7
20-403 (1)
TROUBLESHOOTING
E957
Error Code in Electrical System E957 (Engine power failure (2)) User Code
Error Code
Failure Code
E15
E957
D1D0KB
Failure content
Failure phenomenon
Engine power failure (2) (Engine controller system)
• When the starting switch is turned OFF, the source voltage of the controller is above 10 V.
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.
Relative information Cause
Presumed cause and standard value in normalcy
Engine controller power 1 supply relay defective (Internal short-circuiting)
Replace the power supply relay with another one. If the condition becomes normal, the relay is defective.
R22
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring Between wiring harness between E13 (female) (1), (2), 2 harness (21) and R22 (female) (5) and grounding (Contact with 24 V circuit) Between wiring harness between R22 (female) (1) and J02 (male) (1) or between R22 (female) (1) and related circuits and grounding
Voltage
Below 1 V
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF and ON positions during the troubleshooting. 3
20-404 (1)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Engine controller defective
E13
Starting switch
Voltage
Between (1), (2), (21) and (11), (31), (32)
OFF
Below 1 V
ON
20 – 30 V
PC750, 800-7
TROUBLESHOOTING
E957
Circuit diagram related to engine controller power supply
PC750, 800-7
20-405 (1)
TROUBLESHOOTING
E95A
Error Code in Electrical System E95A (Engine Q-adj. sw. signal error) User Code
Error Code
Failure Code
—
E95A
DB2AMA
Failure content
Failure phenomenon
Engine Q-adj. sw. signal error (Engine controller system)
• The fuel injection amount adjustment switch of the controller is not set to the correct position.
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. • Setting of the fuel injection amount adjustment switch cannot be changed.
Relative information
• Setting (Set position) of the fuel injection amount adjustment switch can be checked in the monitoring function. (Code No. 36800: Right fuel injection amount adjustment switch, 36801: Left fuel injection amount adjustment switch)
Presumed cause and standard value in normalcy
Phenomenon occurring on machine
Cause Setting of fuel injection amount adjustment 1 switch of engine controller defective
2
20-406 (1)
Engine controller defective
Standard value in normalcy and references for troubleshooting If the fuel injection amount adjustment switch 1 (right) or 2 (left) is set in [F], its setting is wrong.
If the cause is not detected, engine controller may be defective.
PC750, 800-7
TROUBLESHOOTING
E96A
Error Code in Electrical System E96A (Engine coolant sensor Lo error) User Code
Error Code
Failure Code
E15
E96A
DGE3L6
Failure phenomenon
Engine coolant sensor Lo error (Engine controller system)
Failure content
• The signal voltage from the engine water low temperature sensor is above 4.5 V.
Response from controller
• The signal of the engine water low temperature sensor is kept at 20°C (If the signal of the high temperature sensor is effective, it is used as a substitute). • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.
Relative information
• Input from the engine water low temperature sensor (voltage and water temperature) can be checked in the monitoring function. (Code No. 04105: Engine water temperature sensor voltage Lo, 04107: Engine water temperature (Low temperature)) Cause
Presumed cause and standard value in normalcy
Engine water low temperature sensor 1 defective (Internal disconnection or short circuiting) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. TWL (male)
Resistance value
Between (A) and (B)
0.3 k – 9 kz
Between (A), (B) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E12 (female) (37) and TWL (female) (A)
Resistance value
Below 1 z
Wiring harness between E12 (female) (39), J09, and TWL (female) (B)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (37) and TWL (female) (A) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
20-408 (1)
Engine controller defective
E12
Resistance value
Between (37) and (39)
0.3 k – 9 kz
Between (37), (39) and grounding
Above 1 Mz
PC750, 800-7
TROUBLESHOOTING
E96A
Circuit diagram related to engine water temperature sensor (for low temperature and high temperature)
PC750, 800-7
20-409 (1)
TROUBLESHOOTING
E970
Error Code in Electrical System E970 (PCV1 over current) User Code
Error Code
Failure Code
E11
E970
AD11KB
Failure content
Failure phenomenon
PCV1 over current (Engine controller system)
• Abnormal current flowed in the fuel supply pump PCV1 circuit.
• Power to the fuel supply pump PCV1 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1. Cause
Presumed cause and standard value in normalcy
Fuel supply pump PCV1 defective 1 (Internal short circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. PCV1 (male)
Resistance value
Between (1) and (2)
2.3 – 5.3 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E13 (female) (12) and PCV1 (female) (1)
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between E13 (female) (12) and 3 harness PCV1 (female) (1) (Contact with 24 V circuit) Between wiring harness between E13 (female) (22) and PCV1 (female) (2)
Voltage
Below 1 V
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
20-410 (1)
Engine controller defective
E13 (female)
Resistance value
Between (12) and (22)
2.3 – 5.3 z
Between (12), (22) and grounding
Above 1 Mz
PC750, 800-7
TROUBLESHOOTING
E970
Circuit diagram related to fuel supply pump PCV1
PC750, 800-7
20-411 (1)
TROUBLESHOOTING
E971
Error Code in Electrical System E971 (PCV2 over current) User Code
Error Code
Failure Code
E11
E971
AD51KB
Failure content
Failure phenomenon
PCV2 over current (Engine controller system)
• Abnormal current flowed in the fuel supply pump PCV2 circuit.
• Power to the fuel supply pump PCV2 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2. Cause
Presumed cause and standard value in normalcy
Fuel supply pump PCV2 defective 1 (Internal short circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. PCV2 (male)
Resistance value
Between (1) and (2)
2.3 – 5.3 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E13 (female) (13) and PCV2 (female) (1)
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between E13 (female) (13) and 3 harness PCV2 (female) (1) (Contact with 24 V circuit) Between wiring harness between E13 (female) (23) and PCV2 (female) (2)
Voltage
Below 1 V
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
20-412 (1)
Engine controller defective
E13 (female)
Resistance value
Between (13) and (23)
2.3 – 5.3 z
Between (13), (23) and grounding
Above 1 Mz
PC750, 800-7
TROUBLESHOOTING
E971
Circuit diagram related to fuel supply pump PCV2
PC750, 800-7
20-413 (1)
TROUBLESHOOTING
E974
Error Code in Electrical System E974 (PCV1 line cut) User Code
Error Code
Failure Code
E11
E974
AD11KA
Failure content
Failure phenomenon
PCV1 line cut (Engine controller system)
• Fuel supply pump PCV1 circuit is disconnected.
• Power to the fuel supply pump PCV1 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1. Cause
Presumed cause and standard value in normalcy
Fuel supply pump PCV1 1 defective (Internal short circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. PCV1 (male)
Resistance value
Between (1) and (2)
2.3 – 5.3 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E13 (female) (12) and PCV1 (female) (1)
Resistance value
Below 1 z
Between wiring harness between E13 (female) (22) and PCV1 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E13 (female) (22) and PCV1 (female) (2)
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
20-414 (1)
Engine controller defective
E13 (female)
Resistance value
Between (12) and (22)
2.3 – 5.3 z
Between (12), (22) and grounding
Above 1 Mz
PC750, 800-7
TROUBLESHOOTING
E974
Circuit diagram related to fuel supply pump PCV1
PC750, 800-7
20-415 (1)
TROUBLESHOOTING
E975
Error Code in Electrical System E975 (PCV2 line cut) User Code
Error Code
Failure Code
E11
E975
AD51KA
Failure content
Failure phenomenon
PCV2 line cut (Engine controller system)
• Fuel supply pump PCV2 circuit is disconnected.
• Power to the fuel supply pump PCV2 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2. Cause
Presumed cause and standard value in normalcy
Fuel supply pump PCV2 1 defective (Internal short circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. PCV2 (male)
Resistance value
Between (1) and (2)
2.3 – 5.3 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E13 (female) (13) and PCV2 (female) (1)
Resistance value
Below 1 z
Between wiring harness between E13 (female) (23) and PCV2 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E13 (female) (23) and PCV2 (female) (2)
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
20-416 (1)
Engine controller defective
E13 (female)
Resistance value
Between (13) and (23)
2.3 – 5.3 z
Between (13), (23) and grounding
Above 1 Mz
PC750, 800-7
TROUBLESHOOTING
E975
Circuit diagram related to fuel supply pump PCV2
PC750, 800-7
20-417 (1)
TROUBLESHOOTING
E977
Error Code in Electrical System E977 (Rail press. sensor error) User Code
Error Code
Failure Code
E11
E977
DH40KX
Failure content
Failure phenomenon
Rail press. sensor error (Engine controller system)
• The signal voltage from the common rail fuel pressure sensor is below 0.7 V or above 4.5 V.
Response from • The machine is driven with limited output. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure) • Special adapter (799-601-9420) is necessary for troubleshooting for common rail fuel pressure sensor. Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting.
Common rail fuel pressure sensor 1 defective (Internal defect)
PFUEL
Voltage
Between (3) and (1)
Power supply
4.6 – 5.4 V
Between (2) and (1)
Signal
0.7 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge.
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Wiring harness between E12 (female) (9), J20, and PFUEL (female) (3)
Resistance value
Below 1 z
Wiring harness between E12 (female) (39), J09, and PFUEL (female) (1)
Resistance value
Below 1 z
Wiring harness between E12 (female) (40) and PFUEL (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (9), J20, and PFUEL (female) (3) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E12 (female) (40) and PFUEL (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between E12 (female) (9), J20, 4 harness and PFUEL (female) (3) and grounding (Contact with 24 V circuit) Between wiring harness between E12 (female) (40) and PFUEL (female) (2) and grounding
Voltage
Below 1 V
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 5
20-418 (1)
Engine controller defective
E12
Voltage
Between (9) and (39)
4.6 – 5.4 V
Between (40) and (39)
0.7 – 4.5 V
PC750, 800-7
TROUBLESHOOTING
E977
Circuit diagram related to common rail fuel pressure sensor
PC750, 800-7
20-419 (1)
TROUBLESHOOTING
E979
Error Code in Electrical System E979 (Rail press. high) User Code
Error Code
Failure Code
E11
E979
AD00L2
Failure content
Failure phenomenon
Rail press. high (Engine controller system)
• The signal circuit of the common rail fuel pressure sensor detected high pressure (level 1).
Response from • The machine is driven with limited output. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Related systems 1 defective
If any other error code or failure code is displayed, carry out troubleshooting for it first.
2 Fuel used improper
Fuel used may be improper. Check it directly.
Electric system of 3 common rail fuel Carry out troubleshooting for error code [E977]. pressure sensor defective Mechanical system of The common rail fuel pressure sensor may have a mechanical defect. Check it 4 common rail fuel directly. pressure sensor defective 5 Overflow valve defective
The overflow valve may have trouble of breakage of spring, wear of seat, or fixing of ball. Check it directly.
6 Overflow piping clogged
The overflow piping may be clogged. Check it directly.
7 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.
Error Code in Electrical System E97A (Rail press. abnormal) User Code E11 Failure content
Error Code
Failure Code
E97A
AD00MA
Failure phenomenon
Rail press. abnormal (Engine controller system)
• The signal circuit of the common rail fuel pressure sensor detected high pressure (level 2).
• The machine is driven with limited output. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
Presumed cause and standard value in normalcy
20-420 (1)
Cause 1
Common rail-related device defective
Standard value in normalcy and references for troubleshooting Carry out troubleshooting for error code [E979].
PC750, 800-7
TROUBLESHOOTING
E97B
Error Code in Electrical System E97B (Rail press. low) User Code
Error Code
Failure Code
E15
E97B
AD10L3
Failure content
Failure phenomenon
Rail press. low (Engine controller system)
• No-pressure feed by fuel supply pump (level 1) occurred.
• The machine is driven with limited output. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.
Relative information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure) Cause
Presumed cause and standard value in normalcy
1
Related systems defective
Standard value in normalcy and references for troubleshooting If any other error code or failure code is displayed, carry out troubleshooting for it first.
2 Fuel used improper
Fuel used may be improper. Check it directly.
Fuel low-pressure circuit 3 device defective
A low-pressure circuit device may be defective. Referring to Note 1, carry out troubleshooting.
4
Fuel filter/strainer clogged
Electrical system of fuel 5 supply pump PCV1 defective 6
Fuel supply pump defective
Common rail fuel 7 pressure sensor defective
The fuel filter/strainer may be clogged. Referring to Note 2, carry out troubleshooting. Carry out troubleshooting for error codes [E970], [E971], [E974], and [E975]. The fuel supply pump may be defective. Check it directly. The common rail fuel pressure sensor may be defective. Check it directly.
8 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly. 9 Fuel injector defective
The fuel injector may be defective. Referring to Note 3, check it directly.
NOTE 1: Check the low-pressure circuit devices for the following points. 1) Insufficiency of fuel 2) Fixing and wear of feed pump and clogging of filter 3) Leakage from and clogging of low-pressure fuel piping 4) Malfunction of bypass valve and installation of wrong part (See Fig. 1) 5) Clogging of fuel filter 6) Entry of fuel in oil pan (Fuel leakage in head cover) • Fuel low-pressure circuit pressure: 0.15 – 0.3 MPa {1.5 – 3.0 kg/cm2}
PC750, 800-7
20-421 (1)
TROUBLESHOOTING
E97B
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) • Overflow valve (1): Spring is seen through both holes. • Bypass valve (2): Spring is seen through hole on nut side. • Fuel inlet joint (3): Gauze filter is seen through both holes.
NOTE 2: Check, clean, and replace the filters and strainers according to the following procedure. 1) Gauze filter: Disassemble and check the gauze filter. If it is clogged, clean it. 2) Strainer on upstream side of gauze filter: If the gauze filter is clogged, clean the upstream strainer too. 3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter. NOTE 3: Judge the condition of the fuel injector by measuring the fuel spill rate. k When performing the follow work, take care not to scald yourself with the fuel which becomes hot (up to 90°C). 1) Disconnect the hose connected to the centralized return spill tube adapters (at the rear of the engine). 2) Connect another hose to the spill tube end so that spill fuel can be received in a container.
20-422 (1)
3) Run the engine and stall at each speed (relieve the arm circuit by moving the arm in). Measure the quantity of the fuel spilling in 1 minute under this condition. a Limit of spill of fuel (Total of spill from 6 cylinders) Stall speed (rpm)
Limit of spill (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
PC750, 800-7
TROUBLESHOOTING
E97C, E97D
Error Code in Electrical System E97C (Rail press. too low) User Code
Error Code
Failure Code
E11
E97C
AD10MB
Failure content
Failure phenomenon
Rail press. too low (Engine controller system)
• No-pressure feed by fuel supply pump (level 2) occurred.
• The machine is driven with limited output and speed. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
Presumed cause and standard value in normalcy
Cause 1
Standard value in normalcy and references for troubleshooting
Common rail-related device defective
Carry out troubleshooting for error code [E97B].
Error Code in Electrical System E97D (Rail press. out of control) User Code
Error Code
Failure Code
E11
E97D
AD10MA
Failure content
Failure phenomenon
Rail press. out of control (Engine controller system)
• Abnormal fuel pressure was generated in the common rail.
• The machine is driven under the normal control. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
Presumed cause and standard value in normalcy
PC750, 800-7
Cause 1
Common rail-related device defective
Standard value in normalcy and references for troubleshooting Carry out troubleshooting for error code [E97B].
20-423 (1)
TROUBLESHOOTING
E980
Error Code in Electrical System E980 (Eng. Controller Abnormality) User Code
Error Code
Failure Code
E10 or E11
E980
DB20KT
Failure content
Failure phenomenon
Eng. Controller Abnormality (Engine controller system)
• The controller has abnormality in it.
• The machine is driven with limited output or all output is turned OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stop and it cannot be started (when user code [E10] is displayed).
Presumed cause and standard value in normalcy
Relative information Cause
Standard value in normalcy and references for troubleshooting
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
2
20-424 (1)
Engine controller defective
Wiring harness between E13 (female) (11), (31), (32) and grounding
Resistance value
Below 1 z
If cause 1 is not detected, the engine controller may be defective. (Since trouble is in the engine controller, troubleshooting cannot be carried out.)
PC750, 800-7
TROUBLESHOOTING
E980
Circuit diagram related to engine controller power supply
PC750, 800-7
20-425 (1)
TROUBLESHOOTING
E981
Error Code in Electrical System E981 (Fuel Injector 1 Disc.) User Code
Error Code
Failure Code
E11
E981
ADA1KA
Failure content
Failure phenomenon
Fuel Injector 1 Disc. (Engine controller system)
• Fuel injector 1 circuit is disconnected.
• Power to the fuel injector 1 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause
Presumed cause and standard value in normalcy
1
Fuel injector 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
3
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN1 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E13 (female) (14) and CN1 (female) (1)
Resistance value
Below 1 z
Wiring harness between E13 (female) (24) and CN1 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E13 (female)
Resistance value
Between (14) and (24)
0.4 – 1.1 z
Circuit diagram related to fuel injector 1
20-426 (1)
PC750, 800-7
TROUBLESHOOTING
E982
Error Code in Electrical System E982 (Fuel Injector 2 Disc.) User Code
Error Code
Failure Code
E11
E982
ADB1KA
Failure content
Failure phenomenon
Fuel Injector 2 Disc. (Engine controller system)
• Fuel injector 2 circuit is disconnected.
• Power to the fuel injector 2 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause
Presumed cause and standard value in normalcy
1
Fuel injector 2 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
3
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN2 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E13 (female) (6) and CN2 (female) (1)
Resistance value
Below 1 z
Wiring harness between E13 (female) (16) and CN2 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E13 (female)
Resistance value
Between (6) and (16)
0.4 – 1.1 z
Circuit diagram related to fuel injector 2
PC750, 800-7
20-427 (1)
TROUBLESHOOTING
E983
Error Code in Electrical System E983 (Fuel Injector 3 Disc.) User Code
Error Code
Failure Code
E11
E983
ADC1KA
Failure content
Failure phenomenon
Fuel Injector 3 Disc. (Engine controller system)
• Fuel injector 3 circuit is disconnected.
• Power to the fuel injector 3 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause
Presumed cause and standard value in normalcy
1
Fuel injector 3 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
3
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN3 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E13 (female) (5) and CN3 (female) (1)
Resistance value
Below 1 z
Wiring harness between E13 (female) (15) and CN3 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E13 (female)
Resistance value
Between (5) and (15)
0.4 – 1.1 z
Circuit diagram related to fuel injector 3
20-428 (1)
PC750, 800-7
TROUBLESHOOTING
E984
Error Code in Electrical System E984 (Fuel Injector 4 Disc.) User Code
Error Code
Failure Code
E11
E984
ADD1KA
Failure content
Failure phenomenon
Fuel Injector 4 Disc. (Engine controller system)
• Fuel injector 4 circuit is disconnected.
• Power to the fuel injector 4 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause
Presumed cause and standard value in normalcy
1
Fuel injector 4 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
3
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN4 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E13 (female) (26) and CN4 (female) (1)
Resistance value
Below 1 z
Wiring harness between E13 (female) (36) and CN4 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E13 (female)
Resistance value
Between (26) and (36)
0.4 – 1.1 z
Circuit diagram related to fuel injector 4
PC750, 800-7
20-429 (1)
TROUBLESHOOTING
E985
Error Code in Electrical System E985 (Fuel Injector 5 Disc.) User Code
Error Code
Failure Code
E11
E985
ADF1KA
Failure content
Failure phenomenon
Fuel Injector 5 Disc. (Engine controller system)
• Fuel injector 5 circuit is disconnected.
• Power to the fuel injector 5 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause
Presumed cause and standard value in normalcy
1
Fuel injector 5 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
3
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN5 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E13 (female) (33) and CN5 (female) (1)
Resistance value
Below 1 z
Wiring harness between E13 (female) (34) and CN5 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E13 (female)
Resistance value
Between (34) and (33)
0.4 – 1.1 z
Circuit diagram related to fuel injector 5
20-430 (1)
PC750, 800-7
TROUBLESHOOTING
E986
Error Code in Electrical System E986 (Fuel Injector 6 Disc.) User Code
Error Code
Failure Code
E11
E986
ADF1KA
Failure content
Failure phenomenon
Fuel Injector 6 Disc. (Engine controller system)
• Fuel injector 6 circuit is disconnected.
• Power to the fuel injector 6 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause
Presumed cause and standard value in normalcy
1
Fuel injector 6 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
3
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN6 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E13 (female) (25) and CN6 (female) (1)
Resistance value
Below 1 z
Wiring harness between E13 (female) (35) and CN6 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E13 (female)
Resistance value
Between (25) and (35)
0.4 – 1.1 z
Circuit diagram related to fuel injector 6
PC750, 800-7
20-431 (1)
TROUBLESHOOTING
E98A
Error Code in Electrical System E98A (Fuel Injector 1 – 3 S/C) User Code
Error Code
Failure Code
E11
E98A
ADAZKB
Failure content
Failure phenomenon
Fuel Injector 1 – 3 S/C (Engine controller system)
• Abnormal current flowed in the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit.
• Power to the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause Fuel injector 1 defective 1 (Internal short-circuiting or grounding fault)
Presumed cause and standard value in normalcy
Fuel injector 2 defective 2 (Internal short-circuiting or grounding fault)
Fuel injector 3 defective 3 (Internal short-circuiting or grounding fault)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN1 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN2 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN3 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Grounding fault of wiring harness 4 (Contact with grounding circuit)
20-432 (1)
Standard value in normalcy and references for troubleshooting
Between wiring harness between E13 (female) (14) and CN1 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E13 (female) (24) and CN1 (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E13 (female) (6) and CN2 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E13 (female) (16) and CN2 (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E13 (female) (5) and CN3 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E13 (female) (15) and CN3 (female) (2) and grounding
Resistance value
Above 1 Mz
PC750, 800-7
TROUBLESHOOTING
Cause
E98A
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between E13 (female) (14) and CN1 (female) (1) and grounding
Voltage
Below 1 V
Between wiring harness between E13 (female) (24) and CN1 (female) (2) and grounding
Voltage
Below 1 V
Voltage
Below 1 V
Voltage
Below 1 V
Between wiring harness between E13 (female) (5) and CN3 (female) (1) and grounding
Voltage
Below 1 V
Between wiring harness between E13 (female) (15) and CN3 (female) (2) and grounding
Voltage
Below 1 V
Short-circuiting of wiring Between wiring harness between E13 (female) (6) and 5 harness CN2 (female) (1) and grounding (Contact with 24 V circuit) Between wiring harness between E13 (female) (16) and CN2 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E13 (female) 6
Engine controller defective
Resistance value
Between (14) and (24)
0.4 – 1.1 z
Between (6) and (16)
0.4 – 1.1 z
Between (5) and (15)
0.4 – 1.1 z
Between (5), (6), (14), (15), (16), (24) and grounding
Above 1 Mz
Circuit diagram related to fuel injectors 1, 2, and 3
PC750, 800-7
20-433 (1)
TROUBLESHOOTING
E98B
Error Code in Electrical System E98B (Fuel Injector 4 – 6 S/C) User Code
Error Code
Failure Code
E11
E98B
ADDZKB
Failure content
Failure phenomenon
Fuel Injector 4 – 6 S/C (Engine controller system)
• Abnormal current flowed in the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit.
• Power to the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause Fuel injector 4 defective 1 (Internal short-circuiting or grounding fault)
Presumed cause and standard value in normalcy
Fuel injector 5 defective 2 (Internal short-circuiting or grounding fault)
Fuel injector 6 defective 3 (Internal short-circuiting or grounding fault)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN4 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN5 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN6 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Grounding fault of wiring harness 4 (Contact with grounding circuit)
20-434 (1)
Standard value in normalcy and references for troubleshooting
Between wiring harness between E13 (female) (26) and CN4 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E13 (female) (36) and CN4 (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E13 (female) (34) and CN5 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E13 (female) (33) and CN5 (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E13 (female) (25) and CN6 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between E13 (female) (35) and CN6 (female) (2) and grounding
Resistance value
Above 1 Mz
PC750, 800-7
TROUBLESHOOTING
Cause
E98B
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between E13 (female) (26) and CN4 (female) (1) and grounding
Voltage
Below 1 V
Between wiring harness between E13 (female) (36) and CN4 (female) (2) and grounding
Voltage
Below 1 V
Voltage
Below 1 V
Voltage
Below 1 V
Between wiring harness between E13 (female) (25) and CN6 (female) (1) and grounding
Voltage
Below 1 V
Between wiring harness between E13 (female) (35) and CN6 (female) (2) and grounding
Voltage
Below 1 V
Short-circuiting of wiring Between wiring harness between E13 (female) (34) and 5 harness CN5 (female) (1) and grounding (Contact with 24 V circuit) Between wiring harness between E13 (female) (33) and CN5 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E13 (female) 6
Engine controller defective
Resistance value
Between (26) and (36)
0.4 – 1.1 z
Between (34) and (33)
0.4 – 1.1 z
Between (25) and (35)
0.4 – 1.1 z
Between (25), (26), (33), (34), (35), (36) and grounding
Above 1 Mz
Circuit diagram related to fuel injectors 4, 5, and 6
PC750, 800-7
20-435 (1)
TROUBLESHOOTING
A000N1
Failure Code in Mechanical System A000N1 (Eng. Hi Out of Std) User Code
Error Code
Failure Code
—
—
A000N1
Failure content
Failure phenomenon
Eng. Hi Out of Std (Mechanical system)
• Engine speed higher than 2,500 rpm is detected while the engine is running.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the engine may be damaged.
Relative information
• Input from the engine speed sensor (rpm) can be checked in the monitoring function. (Code No. 01002: Engine speed)
Presumed cause and standard value in normalcy
Cause Engine overrun 1 (While system is normal)
Standard value in normalcy and references for troubleshooting Check for external and internal causes for abnormal rise of the engine high idling speed, then carry out troubleshooting for the mechanical system of the engine.
2
Engine Ne sensor system If error code [E91B] is displayed, carry out troubleshooting for it. defective
3
Engine G sensor system defective
4
Engine controller defective
PC750, 800-7
If error code [E91C] is displayed, carry out troubleshooting for it. a Turn the engine starting switch ON for the preparations, and keep the engine running during the troubleshooting. Monitoring
Engine
Engine speed
010006 Engine speed
High idling
1,930 – 2,030 rpm
20-437 (1)
TROUBLESHOOTING
AA10NX
Failure Code in Mechanical System AA10NX (Aircleaner Clogging) User Code
Error Code
Failure Code
—
—
AA10NX
Failure content
Failure phenomenon
Aircleaner Clogging (Mechanical system)
• The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine is running.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the engine may be damaged.
Relative information
• If the air cleaner clogging monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function. (Code No. 04501: Monitor input 1) Cause
Presumed cause and standard value in normalcy
1
Air cleaner clogged (While system is normal)
Air cleaner clogging 2 switch defective (Internal disconnection)
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting Check the air cleaner. If it is clogged, clean or replace it. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position or keep the engine running during the troubleshooting. P11 (male) Between (1) and (2)
Air cleaner
Resistance value
Normal
Below 1 z
Clogged
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (5) and P11 (female) (1)
Resistance value
Below 1 z
Wiring harness between P11 (female) (2), J21, and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position or keep the engine running during the troubleshooting. 4 Monitor panel defective
P02 Between (5) and grounding
20-438 (1)
Air cleaner
Voltage
Normal
Below 1 V
Clogged
20 – 30 V
PC750, 800-7
TROUBLESHOOTING
AA10NX
Circuit diagram related to air cleaner clogging switch
PC750, 800-7
20-439 (1)
TROUBLESHOOTING
AB00KE
Failure Code in Mechanical System AB00KE (Charge Voltage Low) User Code
Error Code
Failure Code
—
—
AB00KE
Failure content
Failure phenomenon
Charge Voltage Low (Mechanical system)
• Signal voltage from alternator is below 20 V while the engine is running.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the battery may not be charged.
Relative information
• If the charge level monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the alternator (Voltage, ON or OFF) can be checked in the monitoring function. (Code No. 04300: Charge voltage, 04501: Monitor input 2) Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
1
Alternator defective (Internal defect)
Alternator
Engine
Voltage
Between terminal R and grounding
Above low idling
Above 20 V
Presumed cause and standard value in normalcy
If the voltage is abnormal, check the belt tension too. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (11), J02, and alternator terminal R
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (11), J02, and alternator terminal R, or between P02 (female) (11), D01, J01, and starting switch terminal BR, or between P02 (female) (11), battery relay terminal BR and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 4 Monitor panel defective
20-440 (1)
P02
Engine
Voltage
Between (11) and grounding
Above low idling
Above 20 V
PC750, 800-7
TROUBLESHOOTING
AB00KE
Circuit diagram related to engine preheating, starting, and charging circuits
PC750, 800-7
20-441 (1)
TROUBLESHOOTING
B@BAZG
Failure Code in Mechanical System B@BAZG (Eng. Oil Press. Low) User Code
Error Code
Failure Code
E11
E924
B@BAZG
Failure content
Failure phenomenon
Eng. Oil Press. Low (Mechanical system)
• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of the high-pressure switch is closed (connected to grounding) while the engine speed is above 600 rpm. • The signal circuit of the low-pressure switch is opened (disconnected from grounding) and the signal circuit of the high-pressure switch is closed (connected to grounding) while the engine speed is above 1,300 rpm.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the engine may be damaged.
Relative information
• When this failure occurs, the error code is displayed only when the user code is turned ON and the failure code is recorded in only the mechanical system of the failure history. • If the engine oil pressure monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the engine oil pressure switch (ON or OFF) can be checked in the monitoring function. (Code No. 17400: Engine controller input)
Presumed cause and standard value in normalcy
Cause Engine oil pressure 1 lowered (While system is normal) 2
Engine oil pressure switch system defective
Standard value in normalcy and references for troubleshooting Check the engine oil pressure. If it is abnormal, find out the cause and check the engine for damage, then repair. Carry out troubleshooting for error code [E936]. a Turn the engine starting switch OFF for the preparations, and hold it in the ON position or start the engine during the troubleshooting.
3
Engine controller defective
E11
Engine
Voltage
Between (21) and grounding (Low-pressure switch signal)
Stopped
Below 1 V
Low idling
20 – 30 V
Stopped
Below 1 V
Above 1,300 rpm
20 – 30 V
Between (15) and grounding (High-pressure switch signal)
When carrying out troubleshooting while the engine is running, wait for 15 seconds after the engine is started.
20-442 (1)
PC750, 800-7
TROUBLESHOOTING
B@BAZG
Circuit diagram related to engine oil pressure sensors (for low pressure and high pressure)
PC750, 800-7
20-443 (1)
TROUBLESHOOTING
B@BAZK
Failure Code in Mechanical System B@BAZK (Eng. Oil Level Low) User Code
Error Code
Failure Code
—
—
B@BAZK
Failure content
Failure phenomenon
Eng. Oil Level Low (Mechanical system)
• The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the engine is stopped.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the engine may be damaged.
Relative information
• If the engine oil level monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function. (Code No. 04501: Monitor input 2) Cause
1
Engine oil level low (While system is normal)
Standard value in normalcy and references for troubleshooting Check the oil level in the engine oil pan. If it is low, add oil. (If it is reduced frequently, find out the cause.)
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 2
Engine oil level switch defective
OL (male) Between (1) and grounding
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Engine oil level
Resistance value
Normal level
Below 1 z
Below normal level
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (8) and OL (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Monitor panel defective
P02 Between (8) and grounding
Engine oil level
Voltage
Normal level
Below 1 V
Below normal level
20 – 30 V
Circuit diagram related to engine oil level switch
20-444 (1)
PC750, 800-7
TROUBLESHOOTING
B@BCNS
Failure Code in Mechanical System B@BCNS (Eng. Water Overheat) User Code
Error Code
Failure Code
—
—
B@BCNS
Failure content
Failure phenomenon
Eng. Water Overheat (Mechanical system)
• The signal circuit of the engine water high temperature sensor detected temperature above 105°C.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the engine may be damaged.
Relative information
• If the engine water temperature monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the engine water high temperature sensor (water temperature and voltage) can be checked in the monitoring function. (Code No. 04102: Engine water temperature (High), 04106: Engine water temperature sensor voltage Hi)
Presumed cause and standard value in normalcy
Cause 1
Engine overheated (While system is normal)
Engine water high 2 temperature sensor system defective
3
Engine controller defective
Standard value in normalcy and references for troubleshooting Check the engine for overheating. If it has been overheated, find out the cause and check the engine for damage, then repair. Carry out troubleshooting for "Display of engine water temperature gauge on monitor panel is abnormal" in E-mode. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E12 (female)
Engine water temperature
Resistance value
Between (27) and (39)
105°C
3.28 kz
Circuit diagram related to engine water temperature sensor (for low temperature and high temperature)
PC750, 800-7
20-445 (1)
TROUBLESHOOTING
B@BCZK
Failure Code in Mechanical System B@BCZK (Eng. Water Lvl Low) User Code
Error Code
Failure Code
—
—
B@BCZK
Failure content
Failure phenomenon
Eng. Water Lvl Low (Mechanical system)
• The signal circuit of the radiator water level switch is opened (disconnected from grounding) while the engine is running.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the engine will overheat.
Relative information
• If the radiator water level monitor on the monitor panel lights up in red while the engine is stopped (the starting switch is at the ON position), this failure code is recorded. • Input from the radiator water level switch (ON or OFF) can be checked in the monitoring function. (Code No. 04500: Monitor input 1) Cause
1
Sub-tank water level low (While system is normal)
Presumed cause and standard value in normalcy
Radiator water level 2 switch 1 defective (Internal disconnection)
Radiator water level 3 switch 2 defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting Check the radiator sub-tank water level. If it is low, add water. (If it is reduced frequently, find out the cause.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. P08 (male) Between (1) and (2)
Sub-tank water level
Resistance value
Within normal level
Below 1 z
Below LOW level
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. P20 (male) Between (1) and (2)
Sub-tank water level
Resistance value
Within normal level
Below 1 z
Below LOW level
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 4 (Disconnection or defective contact with connector)
Wiring harness between P02 (female) (3) and P08 (female) (1)
Resistance value
Below 1 z
Wiring harness between P08 (female) (2) and P20 (female) (1)
Resistance value
Below 1 z
Wiring harness between P20 (female) (2) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5 Monitor panel defective
P02 Between (3) and grounding
20-446 (1)
Sub-tank water level
Voltage
Within normal level
Below 1 V
Below LOW level
20 – 30 V
PC750, 800-7
TROUBLESHOOTING
B@BCZK
Circuit diagram related to radiator water level switch
PC750, 800-7
20-447 (1)
TROUBLESHOOTING
B@HANS
Failure Code in Mechanical System B@HANS (Hydr. Oil Overheat) User Code
Error Code
Failure Code
—
—
B@HANS
Failure content
Failure phenomenon
Hydr. Oil Overheat (Mechanical system)
• The signal of the hydraulic oil temperature sensor rises above 102°C while the engine is running.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the hydraulic equipment may be damaged.
Relative information
• If the hydraulic oil temperature monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the hydraulic oil temperature sensor (temperature) can be checked in the monitoring function. (Code No. 04401: Hydraulic oil temperature) Cause
Presumed cause and standard value in normalcy
1
Hydraulic oil overheated (While system is normal)
Hydraulic oil temperature 2 sensor defective (Internal short-circuiting)
Standard value in normalcy and references for troubleshooting Check the hydraulic oil for overheating. If it has been overheated, find out the cause and check the hydraulic equipment for damage, then repair. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. P10 (male) Between (1) and (2) Between (1) and grounding
Grounding fault of wiring harness 3 (Contact with grounding circuit)
10 – 100°C
Resistance value 90 – 3.5 kz Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (12) and P10 (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Monitor panel defective
P02
20-448
Hydraulic oil temperature
Between (12) and (13) Between (12) and grounding
(1)
Hydraulic oil temperature
Resistance value 90 – 3.5 kz
10 – 100°C
Above 1 Mz
PC750, 800-7
TROUBLESHOOTING
B@HANS
Circuit diagram related to hydraulic oil temperature sensor
PC750, 800-7
20-449 (1)
TROUBLESHOOTING
DA80MA
Failure Code in Mechanical System DA80MA (Auto. Lub Abnormal.) a This failure code is applicable only when the auto grease device is installed.
20-450 (1)
PC750, 800-7
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE).................................................................. 20-502 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-504 E-1 Engine does not start (Engine does not rotate) .................................................................................... 20-505 E-2 Preheater does not operate.................................................................................................................. 20-508 E-3 Auto engine warm-up device does not work ........................................................................................ 20-510 E-4 Auto-decelerator does not operate ....................................................................................................... 20- 511 E-5 All work equipment, swing and travel do not move .............................................................................. 20-512 E-6 Machine push-up function does not operate normally.......................................................................... 20-514 E-7 Boom shockless function does not operate normally ........................................................................... 20-516 E-8 Any item is not displayed on monitor panel .......................................................................................... 20-518 E-9 Part of display on monitor panel is missing .......................................................................................... 20-519 E-10 Monitor panel displays contents irrelevant to the model .................................................................... 20-519 E-11 Fuel level monitor red lamp lights up while engine is running ............................................................ 20-520 E-12 Engine water thermometer does not display normally ....................................................................... 20-522 E-13 Hydraulic oil temperature gauge does not display correctly ............................................................... 20-524 E-14 Fuel gauge does not display correctly ................................................................................................ 20-525 E-15 Swing lock monitor does not display correctly.................................................................................... 20-526 E-16 When monitor switch is operated, nothing is displayed...................................................................... 20-528 E-17 Windshield wiper and window washer do not work ............................................................................ 20-530 E-18 Alarming buzzer cannot be cancelled ................................................................................................ 20-538 E-19 "Boom RAISE" is not correctly displayed in monitor function ............................................................. 20-539 E-20 "Boom LOWER" is not correctly displayed in monitor function........................................................... 20-540 E-21 "Arm IN" is not correctly displayed in monitor function ....................................................................... 20-541 E-22 "Arm OUT" is not correctly displayed in monitor function ................................................................... 20-542 E-23 "Bucket CURL" is not correctly displayed in monitor function ............................................................ 20-543 E-24 "Bucket DUMP" is not correctly displayed in monitor function............................................................ 20-544 E-25 "SWING" is not correctly displayed in monitor function ...................................................................... 20-545 E-26 "Left travel" is not displayed normally in monitoring function.............................................................. 20-548 E-27 "Right travel" is not displayed normally in monitoring function ........................................................... 20-550 E-28 "Service" is not correctly displayed in monitor function ...................................................................... 20-552 E-29 Air conditioner does not work ............................................................................................................. 20-554 E-30 Step light does not light up or go off ................................................................................................... 20-555 E-31 Electric grease gun does not operate................................................................................................. 20-560 E-32 Travel alarm does not sound or does not stop sounding.................................................................... 20-562
PC750, 800-7
20-501 (1)
TROUBLESHOOTING
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE) Connection table of circuit breakers a This connection table shows the devices to which each power supply of the circuit breakers supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers first to see if the power is supplied normally. Type of power supply
Circuit breaker No. 1 2 Switch power supply (Battery relay 3 terminal M) 4 5 6 Constant power 7 supply (Battery relay 8 terminal B) 9
20-502 (1)
Circuit breaker capacity 40A 20A 20A 20A 20A 20A 20A 20A 20A
Destination of power Fuse box (Fuses No. 1 – 15) Boom working lamp, right head lamp Grease pump Pump controller power source Head lamp on cab Starting switch and engine controller (Power supply control) Engine controller power supply relay (Power supply drive) Monitor panel Fuse box (Fuses No. 16 – 20)
PC750, 800-7
TROUBLESHOOTING
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)
Connection table of fuse boxes a This connection table shows the devices to which each power supply of the fuse boxes supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). a When carrying out troubleshooting for a displayed code, you should check the fuse boxes to see if the power is supplied normally. Type of power supply
Switch power supply (Circuit breaker 1)
Switch power supply (Circuit breaker 1)
Switch power supply (Circuit breaker 1)
Constant power supply (Circuit breaker 9)
PC750, 800-7
Fuse No.
Fuse capacity
1
10A
2
10A
3
10A
4
20A
5
10A
6 7 8 9 10 11 12 13 14 15 16 17 18 19
10A 10A 10A 10A 20A 25A 20A 20A 10A 10A 10A 10A 10A 10A
20
10A
Destination of power TVC solenoid (for emergency pump drive) Swing holding brake solenoid (for swing brake release) Starting motor cut-out relay Machine push-up solenoid Boom shockless solenoid PPC lock solenoid Cigarette lighter Windshield washer motor Horn Flash light (Spare) Rotary lamp (Spare) Radio Monitor panel Air conditioner unit (Spare) (Spare) Service power supply (M32 connector) DC/DC converter Radio — (Engine compartment lamp) Room lamp Step light Pump controller power source (for step light) Step light switch
20-503 (1)
TROUBLESHOOTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE a The following information are edited and contained in the "Information Contained in Troubleshooting Table". You are required to proceed with troubleshooting after fully grasping the contents. Failure information
Phenomena occurring on machine
Relative information
Information on occurred failures and troubleshooting Cause
• The standard values in normalcy by which to judge "good" or "no good" about presumed causes. • References for making judgement of "good" or "no good"
Presumed cause and standard value in normalcy
1
2
3
4
5
Standard value in normalcy and references for troubleshooting
Cause for presumed failure (The attached No. for filing and reference purpose only. It does not stand for any priority)
• Failure due to disconnection Defective contact with connector or disconnection of wiring harness has occurred. • Grounding fault A wiring harness that is not originally connected with a grounding circuit is in contact with it. • Failure due to short-circuiting A wiring harness that is not originally connected with a power source circuit (24 V) is in contact with it.
1) Connector denotation method and handling of T-adapters Insert or connect T-adapters in the following manner, unless specifically otherwise instructed. • If there is no indication of (male) or (female) in the connector No., pull off a connector and insert a T-adapter into both sides of male and female. • If there is an indication of (male9 and (female) in the connection No., pull off a connector and insert a T-adapter into only one side of (male) or (female). 2) Description sequence of pin No. and handling of circuit tester leads Connect the positive lead (+) and negative lead (–) for troubleshooting in the following manner unless specifically otherwise instructed. • Connect the positive lead (+) to a pin No. marked at the front or wiring harness. • Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred. • Connector No.: Indicates (Type - numbers of a pin) (color) • Arrow: Roughly indicates the location in the machine where it is installed.
20-504 (1)
PC750, 800-7
TROUBLESHOOTING
E-1
E-1 Engine does not start (Engine does not rotate) Failure information
• The engine does not start. (Engine does not rotate)
Relative information
• The engine starting circuit is equipped with the start lock mechanism of safety lock lever type. Cause
1
2
Battery capacity insufficient Circuit breakers No. 1 or 6 or fuse 3 defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Battery voltage
Electrolyte specific gravity
Above 24 V
Above 1.26
If a circuit breaker is turned OFF or a fuse is broken, the circuit probably has grounding fault (See cause 9). a Turn the engine starting switch OFF for the preparations, and hold it in the ON position or start the engine during the troubleshooting.
3
Starting switch defective (Internal disconnection)
H15 (male)
Starting switch
Resistance value
OFF
Above 1 Mz
ON
Below 1 z
Presumed cause and standard value in normalcy
Between (1) and (4)
Safety lock switch 4 defective (Internal short-circuiting)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S14 (female)
Safety lock lever
Resistance value
FREE
Above 1 Mz
LOCK
Below 1 z
Between (1) and (3)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Starting motor cut-out 5 relay defective (Internal defect)
R11 (female) and R13 (female)
Resistance value
Between (1) and (2)
100 – 500 z
Between (3) and (5)
Above 1 Mz
Between (3) and (6)
Below 1 z
a Turn the engine starting switch OFF for the preparations (with the wiring harness connected), and start the engine for troubleshooting. Starting motor
Starting motor defective 6 (Internal defect)
Voltage
Between B and grounding
B (Power supply)
20 – 30 V
Between ST (1) and grounding
S (Start)
20 – 30 V
Between ST (2) and grounding
R (Charge)
Below 1 V
If the above voltages are normal and the starting motor does not rotate, the starting motor has a defect in it or the engine is defective. Alternator defective 7 (Internal short-circuiting)
PC750, 800-7
a Turn the engine starting switch OFF for the preparations (with only wiring harness R disconnected), and hold it in the ON position during the troubleshooting. Alternator
Voltage
Between terminal R and grounding
Below 1 V
20-505 (1)
TROUBLESHOOTING
Cause
E-1
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Presumed cause and standard value in normalcy
Disconnection of wiring harness 8 (Disconnection or defective contact with connector)
Wiring harness between battery relay terminal B and B16
Resistance value
Below 1 z
Wiring harness between B26, J14, and H15 (female) (1)
Resistance value
Below 1 z
Wiring harness between H15 (female) (4), J01, and R11 (female) (5)
Resistance value
Below 1 z
Wiring harness between R11 (female) (3) and ST (female) (1)
Resistance value
Below 1 z
Wiring harness between FB1-3 and S14 (male) (1)
Resistance value
Below 1 z
Wiring harness between S14 (male) (3) and R11 (female) (1)
Resistance value
Below 1 z
Wiring harness between R11 (female) (2) and R13 (female) (6)
Resistance value
Below 1 z
Wiring harness between R13 (female) (3), J04, J22, and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Grounding fault of wiring harness 9 (Contact with grounding circuit)
Between wiring harness between B26, J14, and H15 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between H15 (female) (4), J01, and R11 (female) (5) and grounding
Resistance value
Above 1 Mz
Between wiring harness between R11 (female) (3) and ST (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between FB1-3 and S14 (male) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between S14 (male) (3) and R11 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between R11 (female) (2) and R13 (female) (6) and grounding
Resistance value
Above 1 Mz
Between wiring harness between R13 (female) (2) and P02 (female) (14) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between ST (female) (2) and 10 harness (Contact with 24 V circuit) alternator terminal R or between ST (female) (2), J02 and D01 (female) (6) or between ST (female) (2) and P02 (female) (11) and grounding
20-506 (1)
Voltage
Below 1 V
PC750, 800-7
TROUBLESHOOTING
E-1
Electrical Circuit Diagram for Engine Preheat, Start and Battery Charging
PC750, 800-7
20-507 (1)
TROUBLESHOOTING
E-2
E-2 Preheater does not operate Failure information
• The preheater does not operate.
Relative information
• The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about 30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds). • Input of the preheating signal (ON or OFF) can be checked in the monitoring function. (Code No. 04500: Monitor input 1)
Presumed cause and standard value in normalcy
Cause
(1) When the starting switch is turned to the HEAT position, the preheating monitor does not light up.
Standard value in normalcy and references for troubleshooting
Starting switch system 1 defective
If the preheater does not operate (the heater unit is not warmed), carry out troubleshooting (2).
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (18) and J02 (male) (7)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations , and hold it in the OFF or HEAT position during troubleshooting. 3 Monitor panel defective
P02
Starting switch
Voltage
Between (18) and grounding
OFF
Below 1 V
HEAT
20 – 30 V
Failure information
• The preheater does not operate.
Relative information
• Check that the starting motor rotates normally. • (If the starting motor does not rotate, carry out troubleshooting in "Engine does not start".) Cause
(2) When the starting switch is turned to the HEAT position, the heater unit is not warmed.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF or HEAT position during troubleshooting.
1
Starting switch defective (Internal disconnection)
H15 (male) Between (1) and (3)
Starting switch
Resistance value
OFF
Above 1 Mz
HEAT
Below 1 z
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations (with the wiring harness connected), and hold it in the OFF or HEAT position during troubleshooting. 2
Heater relay defective (Internal disconnection)
Intake air heater 3 defective (Internal disconnection)
Disconnection of wiring harness 4 (Disconnection or defective contact with connector)
20-508 (1)
Heater relay
Starting switch
Continuity and resistance value
Between coil terminal and grounding
OFF
Continued
Between contact terminals
HEAT
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Intake air heater Between terminals
Continuity Continued
Wiring harness between H15 (female) (3), J02, and heater relay terminal
Resistance value
Below 1 z
Wiring harness between starting motor terminal B and heater relay
Resistance value
Below 1 z
Wiring harness between heater relay and intake air heater
Resistance value
Below 1 z
Wiring harness between intake air heater and engine
Resistance value
Below 1 z
PC750, 800-7
TROUBLESHOOTING
E-2
Electrical Circuit Diagram for Engine Preheat, Start and Battery Charging
PC750, 800-7
20-509 (1)
TROUBLESHOOTING
E-3
E-3 Auto engine warm-up device does not work Failure information
• The auto engine warm-up device does not work.
Relative information
• The auto engine warm-up device is activated, when the engine cooling water temperature is below 30°C, and raise the engine rotation up to 1,200 rpm. • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more than 3 seconds, when the engine starting switch is in the ON position or after the engine is started. • If the engine water temperature is below 10°C, the turbocharger protection function operates to keep the engine speed below 1,000 rpm for up to 5 seconds after the engine is started.
Presumed cause and standard value in normalcy
Cause
a Turn the starting switch ON for the troubleshooting (monitoring). Monitoring code 1
Engine cooling water temperature signal fault
04107
Item
Normal display
Engine cooling water temperature (low temperature)
Compare the monitor indication with the actual engine cooling water temperature.
If the display on the monitor panel is abnormal, carry out troubleshooting in "Engine water thermometer does not display normally". 2
20-510 (1)
Standard value in normalcy and references for troubleshooting
Engine controller defective
If cause 1 is not detected, the engine controller may be defective. (Since trouble is in the engine controller, troubleshooting cannot be carried out.)
PC750, 800-7
TROUBLESHOOTING
E-4
E-4 Auto-decelerator does not operate Failure information
• The auto-decelerator does not operate.
Relative information
• Since the auto-decelerator is set to 1,400 rpm, it does not operate if the fuel control dial is not set above this level. • Check the display on the monitor panel while the engine is running. • If the display on the monitor panel is abnormal, carry out troubleshooting in "*** is not displayed normally in monitoring function". Cause
1
Boom RAISE signal defective
Boom LOWER signal 2 defective
3 Arm IN signal defective
Presumed cause and standard value in normalcy
4 Arm OUT signal defective
5
Bucket CURL signal defective
Bucket DUMP signal 6 defective
7 Swing signal defective
8
Left travel signal defective
9
Right travel signal defective
10 Service signal defective
11 Pump controller defective 12
Engine controller defective
PC750, 800-7
Standard value in normalcy and references for troubleshooting Monitoring code
Item
Normal display
01900 Pressure switch 1
Boom RAISE
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01900 Pressure switch 1
Boom LOWER
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01900 Pressure switch 1
Arm IN
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01900 Pressure switch 1
Arm OUT
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01901 Pressure switch 2
Bucket CURL
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01901 Pressure switch 2
Bucket DUMP
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01900 Pressure switch 1
Swing
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01901 Pressure switch 2
Left travel
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01900 Pressure switch 1
Right travel
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01901 Pressure switch 2
Service
Lever operated: ON Lever in neutral: OFF
If causes 1 – 10 are not detected, the pump controller may be defective. (Since trouble is in the pump controller, troubleshooting cannot be carried out.) If causes 1 – 10 are not detected, the engine controller may be defective. (Since trouble is in the pump controller, troubleshooting cannot be carried out.)
20-511 (1)
TROUBLESHOOTING
E-5
E-5 All work equipment, swing and travel do not move Failure information
• All the work equipment, swing and travel do not move.
Relative information
— Cause
1 Fuse No. 3 fault
Presumed cause and standard value in normalcy
Safety lock switch 2 defective (Internal disconnection)
PPC lock solenoid fault (Internal disconnection, 3 short-circuiting, or grounding fault)
Assembled-type diode 4 D01 fault (Internal short-circuiting)
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. (See Cause 6.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S14 (female)
Safety lock lever
Between (1) and (2)
Resistance value
Free
Below 1 z
Lock
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male)
Resistance value (Continuitiy)
Between (4) and (8)
Above 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 5 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 6 (Contact with grounding (GND) circuit)
20-512 (1)
Standard value in normalcy and references for troubleshooting
Wiring harness between FB1-3 outlet and S14 (male) (1)
Resistance value
Below 1 z
Wiring harness from S14 (male) (2) and V08 (female) (2)
Resistance value
Below 1 z
Wiring harness between V08 (female) (1) to J14 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-3 outlet and S14 (male) (1) and grounding
Resistance value
Above 1 Mz
Wiring harness from S14 (male) (2) to V08 (female) (2), or between wiring harness between S14 (male) (2) and D01 (female) (4) and grounding
Resistance value
Above 1 Mz
PC750, 800-7
TROUBLESHOOTING
E-5
Electrical Circuit Diagram for PPC Lock Solenoid
PC750, 800-7
20-513 (1)
TROUBLESHOOTING
E-6
E-6 Machine push-up function does not operate normally Failure information
• The machine push-up function does not operate normally.
Relative information
• When the machine push-up function is set in the high pressure position, the solenoid is turned OFF.
Presumed cause and standard value in normalcy
Cause Machine push-up switch 1 defective (Internal short-circuiting)
(1) The machine push-up function does not operate.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M38 (female) Between (1) and (2)
Machine push-up switch
Resistance value
Low pressure position
Below 1 z
High pressure position
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during troubleshooting. Short-circuiting of wiring 2 harness Between wiring harness between M38 (female) (2), J06 (Contact with 24 V circuit) and V05 (female) (2) or between M38 (female) (2) and Voltage Below 1 V D04 (female) (1) and grounding
Circuit diagram related to machine push-up solenoid
20-514 (1)
PC750, 800-7
TROUBLESHOOTING
E-6
Failure information
• The machine push-up function does not operate normally.
Relative information
• When the machine push-up function is set in the low pressure position, the solenoid is turned ON. Cause
1 Fuse No. 2 defective
Presumed cause and standard value in normalcy
Machine push-up switch 2 defective (Internal disconnection)
Machine push-up solenoid defective 3 (Internal disconnection, short-circuiting or grounding fault) Assembled-type diode 4 D04 defective (Internal short-circuiting)
(2) The machine push-up function is not turned OFF.
Standard value in normalcy and references for troubleshooting If the fuse is broken, the circuit probably has grounding fault (See cause 6). a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M38 (female)
Machine push-up switch
Resistance value
Low pressure position
Below 1 z
High pressure position
Above 1 Mz
Between (1) and (2)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during troubleshooting. D04 (male)
Resistance value (Continuitiy)
Between (1) and (5)
Above 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 5 (Disconnection or defective contact with connector)
Wiring harness between FB1-2 outlet and M38 (male) (1)
Resistance value
Below 1 z
Wiring harness between M38 (male) (2), J06 and V05 (female) (2)
Resistance value
Below 1 z
Wiring harness between V05 (female) (1), J15, and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 6 (Contact with grounding circuit)
PC750, 800-7
Between wiring harness between FB1-2 outlet and M38 (male) (1) or between FB1-2 outlet and related circuits and grounding
Resistance value
Above 1 Mz
Between wiring harness between M38 (male) (2), J06 and V05 (female) (2) or between M38 (male) (2) and D04 (female) (1) and grounding
Resistance value
Above 1 Mz
20-515 (1)
TROUBLESHOOTING
E-7
E-7 Boom shockless function does not operate normally Failure information
• The boom shockless function does not operate normally.
Relative information
• When the boom shockless function is turned ON, the solenoid is turned OFF.
Presumed cause and standard value in normalcy
Cause
(1) The boom shockless function does not operate.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Boom shockless control 1 switch defective (Internal short-circuiting)
M39 (female) Between (2) and (3)
Boom shockless control switch
Resistance value
OFF
Below 1 z
ON
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between M39 (male) (3), J20, 2 harness (Contact with 24 V circuit) and V09 (female) (2) or between M39 (male) (3) and V10 (female) (2) or between M39 (male) (3) and D05 (female) (1) and grounding
Voltage
Below 1 V
Circuit diagram related to boom shockless solenoid
20-516 (1)
PC750, 800-7
TROUBLESHOOTING
E-7
Failure information
• The boom shockless function does not oper(2) The boom shockless function is not turned OFF. ate normally.
Relative information
• When the boom shockless function is turned OFF, the solenoid is turned ON. Cause
1 Fuse No. 2 defective
Standard value in normalcy and references for troubleshooting If the fuse is broken, the circuit probably has grounding fault (See cause 6). a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Boom shockless control 2 switch defective (Internal disconnection)
M39 (female)
Boom shockless control switch
Between (2) and (3)
Presumed cause and standard value in normalcy
Boom shockless solenoid defective 3 (Internal disconnection or short-circuiting)
Assembled-type diode 4 D05 defective (Internal short-circuiting)
Resistance value
OFF
Below 1 z
ON
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V09 (male) and V10 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D05 (male)
Resistance value (Continuitiy)
Between (1) and (5)
Above 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 5 (Disconnection or defective contact with connector)
Wiring harness between FB1-2 outlet and M39 (male) (2)
Resistance value
Below 1 z
Wiring harness between M39 (male) (3) and V09 (female) (2) or between M39 (male) (3) and V10 (female) (2).
Resistance value
Below 1 z
Wiring harness between V09 (female) (1), V10 (female) (1), J14, and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 6 (Contact with grounding circuit)
PC750, 800-7
Between wiring harness between FB1-2 outlet and M39 (female) (1) or between FB1-2 outlet and related circuits and grounding
Resistance value
Above 1 Mz
Between wiring harness between M39 (male) (3), V09 (female) (2) and V10 (female) (2) or between M39 (male) (3) and D05 (female) (1) and grounding
Resistance value
Above 1 Mz
20-517 (1)
TROUBLESHOOTING
E-8
E-8 Any item is not displayed on monitor panel Failure information
• Any item is not displayed on the monitor panel.
When the starting switch is turned ON, any item is not displayed on the monitor panel.
Relative information Cause 1
Circuit breaker No. 1 or fuse No. 10 defective
Standard value in normalcy and references for troubleshooting If the circuit breaker is turned OFF or the fuse is broken, the circuit probably has grounding fault (See cause 3).
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Wiring harness between P01 (female) (1), (2) and FB110 outlet
Resistance value
Below 1 z
Wiring harness between FB1 inlet and B21
Resistance value
Below 1 z
Wiring harness between B11 and battery relay terminal M
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P01 (female) (1), (2) and FB1-10 outlet and grounding
Resistance value
Above 1 Mz
Between wiring harness between FB1 inlet and B21 and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON or OFF position during troubleshooting. 4 Monitor panel defective
P01 (female)
Starting switch
Voltage, Resistance value
Between (1), (2) and grounding
ON
Voltage: 20 – 30 V
Between (6), (7) and grounding
OFF
Resistance value: Below 1 z
Circuit diagram related to monitor panel power supply
20-518 (1)
PC750, 800-7
TROUBLESHOOTING
E-9, E-10
E-9 Part of display on monitor panel is missing • Part of display on monitor panel is missing
Relative information
—
Presumed cause and standard value in normalcy
Failure information
Cause
Part of the display in the monitor panel is missing during starting switch in ON.
Standard value in normalcy and references for troubleshooting a Turn the starting switch ON during the troubleshooting.
1 Monitor panel LCD fault
2
Monitor panel defective
If all the LCD (Liquid Crystal Display) in the monitor panel light up (i.e. the screen becomes totally white) by the following switching operation, then the monitor panel is normal. • Switching operation: [ ] + [ A ] (push swiches simultaneously.) If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.)
E-10 Monitor panel displays contents irrelevant to the model • The monitor panels displays contents that have nothing to do with the model on which it is installed.
Relative information
—
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting a Turn the starting switch in ON during the troubleshooting (monitoring).
1
Model code signal fault (Internal failure)
Monitoring code
Item
Normal display
00200
Controller model code
PC750-a
If the display on the monitor panel is normal, troubleshoot Error Code [E217]. 2
Monitor panel defective
PC750, 800-7
If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.)
20-519 (1)
TROUBLESHOOTING
E-9, E-10
E-11 Fuel level monitor red lamp lights up while engine is running Failure information
• The fuel level monitor red lamp lighted up while the engine was running.
Relative information
• If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red. Cause
Presumed cause and standard value in normalcy
Fuel level lowered 1 (system in normal condition)
Standard value in normalcy and references for troubleshooting Check the fuel level in the fuel tank. If it is low, add fuel. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
2
Fuel level sensor fault (Internal disconnection)
P06 (male) Between (1) and grounding
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 – 110 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (2) and P06 (female) (1)
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Monitor panel defective
P02 (female) Between (2) and grounding
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 – 110 z
Electrical Circuit Diagram for Fuel Level Sensor
20-520 (1)
PC750, 800-7
TROUBLESHOOTING
E-12
E-12 Engine water thermometer does not display normally (1) While the engine water temperature rises normally, the thermometer does not rise above the white range (C). (2) While the engine water temperature is stabilized normally, the thermometer rises up to the red range (H).
Failure information
• Engine water thermometer does not display normally
Relative information
• The signal of the engine water high temperature sensor for the water thermometer is received from the engine controller through the communication line. • If the engine water high temperature sensor system becomes defective, error code [E934] may be displayed. • Input from the engine water high temperature sensor (voltage and temperature) can be checked in the monitoring function. (Code No. 04106: Engine water sensor voltage Hi, 04102: Engine water temperature (High temperature)) Cause
Presumed cause and standard value in normalcy
Engine water high temperature sensor defective 1 (Internal disconnection, short-circuiting or grounding fault) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. TWH (male)
Resistance value
Between (1) and (2)
3.5 k – 90 kz
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E12 (female) (27) and TWH (female) (1)
Resistance value
Below 1 z
Wiring harness between E12 (female) (39), J09, and TWH (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (27) and TWH (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness (Contact with 24 V circuit) Between wiring harness between E12 (female) (27) and Voltage Below 1 V TWH (female) (1) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5
Engine controller defective
6 Monitor panel defective
20-522 (1)
E12 (female)
Resistance value
Between (27) and (39)
3.5 k – 90 kz
Between (27), (39) and grounding
Above 1 Mz
If causes 1 – 5 are not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.)
PC750, 800-7
TROUBLESHOOTING
E-12
Circuit diagram related to engine water high temperature sensor
PC750, 800-7
20-523 (1)
TROUBLESHOOTING
E-13
E-13 Hydraulic oil temperature gauge does not display correctly • Hydraulic oil temperature rises normally, but the display does not exceed the white range (C). • Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Failure information
• Hydraulic oil temperature gauge does not display correctly
Relative information
• Input from the hydraulic oil temperature sensor can be confirmed in the monitor function. (Code No. 04401: Hydraulic oil temperature)
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF Hydraulic oil temperature position during the troubleshooting. sensor fault P10 (male) Hydraulic oil temperature Resistance value 1 (Internal disconnection, short-circuiting or Between (1) and (2) 90 – 3.5 kz 10 – 100°C grounding fault) Between (1) and grounding Min. 1 Mz Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (12) and P10 (female) (1)
Resistance value
Max. 1 z
Wiring harness between P02 (female) (13) and P10 (female) (2)
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (12) and P10 (female) (1) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness (Contact with 24 V circuit) Between wiring harness between P02 (female) (12) and Voltage Max. 1 V P10 (female) (1) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5 Monitor panel defective
P02 (female)
Hydraulic oil temperature
Between (12) and (13) Between (12) and grounding
Resistance value 90 – 3.5 kz
10 – 100°C
Min. 1 Mz
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
20-524 (1)
PC750, 800-7
TROUBLESHOOTING
E-14
E-14 Fuel gauge does not display correctly • Though fuel was refilled, the display does not exceed the red range (E). • Though the remaining fuel level is low, the display does not drop below the green range (F).
Failure information
• Fuel gauge does not display correctly
Relative information
• Input from the fuel level sensor (voltage) can be confirmed in the monitor function. (Code No. 04200: Fuel sensor voltage) Cause
Presumed cause and standard value in normalcy
Fuel level sensor fault 1 (Internal disconnection or grounding fault)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. P06 (male) Between (1) and grounding
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 – 110 z
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Wiring harness between P02 (female) (2) and P06 (female) (1)
Between wiring harness between P02 (female) (2) and P06 (female) (1) and grounding
Resistance value
Resistance value
Max. 1 z
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness Between wiring harness between P02 (female) (2) and (Contact with 24 V circuit) Voltage Max. 1 V P06 (female) (1) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5 Monitor panel defective
P02 (female) Between (2) and grounding
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 – 110 z
Electrical Circuit Diagram for Fuel Level Sensor
PC750, 800-7
20-525 (1)
TROUBLESHOOTING
E-15
E-15 Swing lock monitor does not display correctly Failure information
(1) Though the swing lock switch was turned ON, the swing lock monitor does not light up. • Swing lock monitor does not display correctly (2) Though the swing lock switch was turned OFF, the swing lock monitor lights up.
Relative information
• Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause
Presumed cause and standard value in normalcy
Swing lock switch fault 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. X05 (female) Between (1) and (2)
Swing lock switch
Resistance value
OFF
Above 1 Mz
ON
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from P02 (female) (17) to J07 and X05 (male) (1)
Resistance value
Below 1 z
Wiring harness from X05 (male) (2) to J08 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from P02 (female) (17) to J07 and X05 (male) (1), or between P02 (female) (17) to C02 (female) (38) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring 4 harness Between wiring harness from P02 (female) (17) to J07 (Contact with 24 V circuit) and X05 (male) (1), or between P02 (female) (17) to C02 (female) (38) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5 Monitor panel defective
20-526 (1)
P02
Swing lock switch
Voltage
Between (17) and grounding
OFF
20 – 30 V
ON
Below 1 V
PC750, 800-7
TROUBLESHOOTING
E-15
Electrical Circuit Diagram for Swing Holding Brake
PC750, 800-7
20-527 (1)
TROUBLESHOOTING
E-16
E-16 When monitor switch is operated, nothing is displayed Failure information
• When monitor switch is operated, nothing is (1) When mode selector switch is operated, working displayed. mode monitor is not displayed.
Relative information
—
Presumed cause and standard value in normalcy
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
Failure information
• When monitor switch is operated, nothing is (2) When LCD monitor adjustment switch is operated, displayed. mode selection screen is not displayed.
Relative information
—
Presumed cause and standard value in normalcy
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
Failure information
• When monitor switch is operated, nothing is (3) When maintenance switch is operated, item selecdisplayed. tion screen is not displayed.
Relative information
—
Presumed cause and standard value in normalcy
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
Failure information
• When monitor switch is operated, nothing is (4) When automatic deceleration switch is operated, displayed. automatic deceleration monitor is not displayed.
Relative information
• When the automatic decelerator does not operate either, conduct the troubleshooting for "Auto-decelertor does not operate".
Presumed cause and standard value in normalcy
Failure information
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
• When monitor switch is operated, nothing is (5) When travel speed selector switch is operated, displayed. travel speed monitor is not displayed.
Relative information Presumed cause and standard value in normalcy
20-528 (1)
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
PC750, 800-7
TROUBLESHOOTING
E-16
Failure information
• When monitor switch is operated, nothing is (6) When wiper switch is operated, wiper monitor is not displayed. displayed.
Relative information
• When the wiper does not operate either, conduct the troubleshooting for "Windshield wiper and window washer do not work".
Presumed cause and standard value in normalcy
PC750, 800-7
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
20-529 (1)
TROUBLESHOOTING
E-17
E-17 Windshield wiper and window washer do not work Double-wiper specification Failure information
• Windshield wiper and window washer do not work
(1) The upper windshield wiper does not operate
Relative information
Presumed cause and standard value in normalcy
Cause Upper wiper motor 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W04 (female)
Continuity and resistance value
Between (3) and (1)
Continued
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P01 (female) (9) and W04 (male) (3)
Resistance value
Below 1 z
Wiring harness between W04 (male) (1) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Monitor panel defective
P01 Between (9) and grounding
Wiper switch OFF
Below 3 V
ON
20 – 30 V (Note)
Note: When the upper wiper and lower wiper are operated simultaneously: Below 3 V intervals)
20-530 (1)
Voltage
20 – 30 V (at regular
PC750, 800-7
TROUBLESHOOTING
E-17
Double-wiper specification Failure information
• Windshield wiper and window washer do not work
(2) Lower windshield wiper does not operate.
Relative information Cause Lower wiper switch 1 defective (Internal disconnection)
Presumed cause and standard value in normalcy
Lower wiper motor 2 defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W06 (female) Between (1) and (2)
Lowe wiper switch
Resistance value
OFF
Above 1 Mz
ON
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W05 (female)
Continuity and resistance value
Between (3) and (1)
Continued
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Monitor panel defective (Lower wiper switch system) 4 Monitor panel defective (Lower wiper motor system)
Wiring harness between P02 (female) (15) and W06 (male) (1)
Resistance value
Below 1 z
Wiring harness between W06 (male) (2), J05, J22, and grounding
Resistance value
Below 1 z
Wiring harness between P01 (female) (10), J04, and W05 (male) (3)
Resistance value
Below 1 z
Wiring harness between W05 (male) (1), J05, J22, and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
Lower wiper switch
Voltage
Between (15) and grounding
OFF
20 – 30 V
ON
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P01
Lower wiper switch
Between (10) and grounding
OFF
Below 3 V
ON
20 – 30 V (Note)
Note: When the upper wiper and lower wiper are operated simultaneously: Below 3 V intervals)
PC750, 800-7
Voltage
20 – 30 V (at regular
20-531 (1)
TROUBLESHOOTING
E-17
Circuit diagram related to wiper motor (double-wiper specification)
20-532 (1)
PC750, 800-7
TROUBLESHOOTING
E-17
Single windshield wiper spec. Failure information
• Windshield wiper and window washer do not work.
(3) The windshield wiper does not work.
Relative information Cause Window rear limit switch fault 1 (Internal disconnection or short-circuiting)
Presumed cause and standard value in normalcy
Windshield wiper motor 2 fault (Internal disconnection)
Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Grounding fault of wiring harness 4 (Contact with grounding (GND) circuit)
Monitor panel fault (Window rear limit switch system) 5
(1)
W03 (female) Between (1) and (2)
Front window
Resistance value
When installed at front
Above 1 Mz
When retracted at rear
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W04 (female)
Continuity and resistance value
Between (3) and (1)
Continued
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P01 (male) (9) and W04 (female) (3)
Resistance value
Below 1 z
Wiring harness between P01 (male) (10) and W04 (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (15) and W03 (male) (2)
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
Front window
Voltage
Between (15) and grounding
When installed at front
20 – 30 V
When retracted at rear
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Monitor panel fault (Windshield wiper motor system)
20-534
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
P01
Windshield wiper switch
Voltage
Between (9) and grounding, Between (10) and grounding
OFF
Below 3 V
ON
Below 3 V 20 – 30 V (Constant cycle)
PC750, 800-7
TROUBLESHOOTING
E-17
Electrical Circuit Diagram for Windshield Wiper Motor (Single windshield wiper spec.)
PC750, 800-7
20-535 (1)
TROUBLESHOOTING
E-17
Failure information
• Windshield wiper and window washer do not work.
Relative information
— Cause
1 Fuse No. 4 defective
Presumed cause and standard value in normalcy
Washer motor defective 2 (Internal disconnection or grounding fault)
Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Grounding fault of wiring harness 4 (Contact with grounding circuit)
(4) Windshield washer does not operate.
Standard value in normalcy and references for troubleshooting If fuse is broken, the circuit probably has grounding fault, etc. (See cause 4.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M28 (male)
Resistance value
Between (1) and (2)
5 – 20 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from FB1-4 outlet to J04 and M28 (female) (1)
Resistance value
Below 1 z
Wiring harness from M28 (female) (2) and P01 (female) (3)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from FB1-4 outlet to J04 and M28 (female) (1), or FB1-4 outlet to D05 (female) (3), and to other relative circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5
Monitor panel defective
P01 Between (3) and grounding
20-536 (1)
Windshield washer switch
Voltage
OFF
20 – 30 V
ON
Below 1 V
PC750, 800-7
TROUBLESHOOTING
E-17
Electrical Circuit Diagram for Window Washer Motor
PC750, 800-7
20-537 (1)
TROUBLESHOOTING
E-18
E-18 Alarming buzzer cannot be cancelled Failure information
• The alarming buzzer cannot be cancelled.
Relative information
• Input from the alarming buzzer stop switch (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Alarming buzzer stop 1 switch fault (Internal disconnection)
P03 (female)
Presumed cause and standard value in normalcy
Between (1) and (2) Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Alarming buzzer stop switch
Resistance value
Release
Above 1 Mz
Depress
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (16) and P03 (male) (1)
Resistance value
Below 1 z
Wiring harness from P03 (male) (2) to J08 to grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 3 harness Between wiring harness between P02 (female) (16) and (Contact with 24 V circuit) Voltage Below 1 V P03 (male) (1) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Monitor panel fault
P02 Between (16) and grounding
Alarming buzzer stop switch
Voltage
Release
20 – 30 V
Depress
Below 1 V
Electrical Circuit Diagram for Alarming Buzzer Stop Switch
20-538 (1)
PC750, 800-7
TROUBLESHOOTING
E-19
E-19 "Boom RAISE" is not correctly displayed in monitor function Failure information
• "Boom RAISE" is not correctly displayed in mon- "Boom RAISE" is not correctly displayed in the moniitor function tor function on the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
Boom RAISE PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S02 (male) Between (1) and (2)
R.H. work equipment control lever
Resistance value
NEUTRAL
Above 1 Mz
Boom RAISE
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (10) and S02 (female) (2)
Resistance value
Below 1 z
Wiring harness between S02 (female) (1) to J12 to J11 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (10) and S02 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness Between wiring harness between C03 (female) (10) and (Contact with 24 V circuit) Voltage Below 1 V S02 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective
C03 Between (10) and grounding
R.H. work equipment control lever
Voltage
NEUTRAL
20 – 30 V
Boom RAISE
Below 1 V
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC750, 800-7
20-539 (1)
TROUBLESHOOTING
E-20
E-20 "Boom LOWER" is not correctly displayed in monitor function Failure information
• "Boom LOWER" is not correctly displayed in monitor function
Relative information
— Cause
Presumed cause and standard value in normalcy
Boom LOWER PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
"Boom LOWER" is not correctly displayed in the monitor function on the monitor panel.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S04 (male) Between (1) and (2)
R.H. work equipment control lever
Resistance value
NEUTRAL
Above 1 Mz
Boom LOWER
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (20) and S04 (female) (2)
Resistance value
Below 1 z
Wiring harness between S04 (female) (1) to J12 to J11 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (20) and S04 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness Between wiring harness between C03 (female) (20) and (Contact with 24 V circuit) Voltage Below 1 V S04 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective
C03 Between (20) and grounding
R.H. work equipment control lever
Voltage
NEUTRAL
20 – 30 V
Boom LOWER
Below 1 V
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
20-540 (1)
PC750, 800-7
TROUBLESHOOTING
E-21
E-21 "Arm IN" is not correctly displayed in monitor function Failure information
• "Arm IN" is not correctly displayed in monitor function
Relative information
— Cause
Presumed cause and standard value in normalcy
Arm IN PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
"Arm IN" is not correctly displayed in the monitor function (special function) on the monitor panel.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S05 (male) Between (1) and (2)
L.H. work equipment control lever
Resistance value
NEUTRAL
Above 1 Mz
Arm IN
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (30) and S05 (female) (2)
Resistance value
Below 1 z
Wiring harness between S05 (female) (1) to J12 to J11 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (30) and S05 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness Between wiring harness between C03 (female) (30) and (Contact with 24 V circuit) Voltage Below 1 V S05 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective
C03 Between (30) and grounding
L.H. work equipment control lever
Voltage
NEUTRAL
20 – 30 V
Arm IN
Below 1 V
Electrical Circuit Diagram for Arm IN PPC Hydraulic Switch
PC750, 800-7
20-541 (1)
TROUBLESHOOTING
E-22
E-22 "Arm OUT" is not correctly displayed in monitor function Failure information
• "Arm OUT" is not correctly displayed in monitor function
Relative information
— Cause
Presumed cause and standard value in normalcy
Arm OUT PPC hydraulic switch defect 1 (Internal disconnection and short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
"Arm OUT" is not correctly displayed in the monitor function (special function) on the monitor panel.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S03 (male)
L.H. work equipment control lever
Resistance value
NEUTRAL
Above 1 Mz
Arm OUT
Below 1 z
Between (1) and (2)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (40) and S03 (female) (2)
Resistance value
Below 1 z
Wiring harness between S03 (female) (1) to J12 to J11 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (40) and S03 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness Between wiring harness between C03 (female) (40) and (Contact with 24 V circuit) Voltage Below 1 V S03 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective
C03
L.H. work equipment control lever
Voltage
NEUTRAL
20 – 30 V
Arm OUT
Below 1 V
Between (40) and grounding
Electrical Circuit Diagram for Arm OUT PPC Hydraulic Switch
20-542 (1)
PC750, 800-7
TROUBLESHOOTING
E-23
E-23 "Bucket CURL" is not correctly displayed in monitor function Failure information
• "Bucket CURL" is not correctly displayed in monitor function
Relative information
— Cause
Presumed cause and standard value in normalcy
Bucket CURL PPC hydraulic switch fault 1 (Internal disconnection and short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
"Bucket CURL" is not correctly displayed in the monitor function (special function) on the monitor panel.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S06 (male) Between (1) and (2)
R.H. work equipment control lever
Resistance value
NEUTRAL
Above 1 Mz
Bucket CURL
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (9) and S06 (female) (2)
Resistance value
Below 1 z
Wiring harness between S06 (female) (1) to J12 to J11 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (9) and S06 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness Between wiring harness between C03 (female) (9) and (Contact with 24 V circuit) Voltage Below 1 V S06 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective
C03 Between (9) and grounding
R.H. work equipment control lever
Voltage
NEUTRAL
20 – 30 V
Bucket CURL
Below 1 V
Electrical Circuit Diagram for Bucket CURL PPC hydraulic Switch
PC750, 800-7
20-543 (1)
TROUBLESHOOTING
E-24
E-24 "Bucket DUMP" is not correctly displayed in monitor function Failure information
"Bucket DUMP" is not correctly displayed in moni- "Bucket DUMP" is not correctly displayed in the montor function itor function (special function) on the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
Bucket DUMP PPC hydraulic switch fault 1 (Internal disconnection and short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S07 (male) Between (1) and (2)
R.H. work equipment control lever
Resistance value
NEUTRAL
Above 1 Mz
Bucket DUMP
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (19) and S07 (female) (2)
Resistance value
Below 1 z
Wiring harness between S07 (female) (1) to J12 to J11 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (19) and S07 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness Between wiring harness between C03 (female) (19) and (Contact with 24 V circuit) Voltage Below 1 V S07 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective
C03 Between (19) and grounding
R.H. work equipment control lever
Voltage
NEUTRAL
20 – 30 V
Bucket DUMP
Below 1 V
Electrical Circuit Diagram for Bucket DUMP PPC hydraulic Switch
20-544 (1)
PC750, 800-7
TROUBLESHOOTING
E-25
E-25 "SWING" is not correctly displayed in monitor function Failure information
• "SWING" is not correctly displayed in monitor function
Relative information
— Cause
Swing PPC hydraulic switch, left, fault 1 (Internal disconnection or short-circuiting)
Presumed cause and standard value in normalcy
Swing PPC hydraulic switch, right, fault 2 (Internal disconnection or short-circuiting)
"SWING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S10 (male) Between (1) and (2)
L.H. work equipment control lever
Resistance value
NEUTRAL
Above 1 Mz
Swing Left
Below 1 z
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S08 (male) Between (1) and (2)
L.H. work equipment control lever
Resistance value
NEUTRAL
Above 1 Mz
Swing Right
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding (GND) circuit)
Wiring harness between C03 (female) (29) to J11 and S08 (female) (2), or wiring harness between C03 (female) (29) and S10 (female) (2)
Resistance value
Below 1 z
Wiring harness between S08 (female) (1) to J11 and grounding
Resistance value
Below 1 z
Wiring harness between S10 (female) (1) to J12 to J11 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (29) to J11 and S08 (female) (2), or wiring harness between C03 (female) (29) and S10 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring 5 harness Wiring harness between C03 (female) (29) to J11 and (Contact with 24 V circuit) S08 (female) (2), or wiring harness between C03 (female) (29) and S10 (female) (2) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 6 Pump controller defective
C03 Between (29) and grounding
PC750, 800-7
L.H. work equipment control lever
Voltage
NEUTRAL
20 – 30 V
Swing Right or left
Below 1 V
20-545 (1)
TROUBLESHOOTING
E-25
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
20-546 (1)
PC750, 800-7
TROUBLESHOOTING
E-26
E-26 "Left travel" is not displayed normally in monitoring function Failure information
• "Left travel" is not displayed normally in the monitoring function.
"Left travel" is not displayed normally in the monitoring function (special function) of the monitor panel.
Relative information Cause Left travel forward PPC oil pressure switch 1 defective (Internal disconnection or short-circuiting)
Presumed cause and standard value in normalcy
Left travel reverse PPC oil pressure switch 2 defective (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S12 (male) Between (1) and (2)
Left travel lever
Resistance value
Neutral
Above 1 Mz
Forward
Below 1 z
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S13 (male) Between (1) and (2)
Left travel lever
Resistance value
Neutral
Above 1 Mz
Reverse
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Wiring harness between C02 (female) (16), J19, and S12 (female) (2) or between C02 (female) (16) and S13 (female) (2)
Resistance value
Below 1 z
Wiring harness between S12 (female) (1), J13, J11, and grounding
Resistance value
Below 1 z
Wiring harness between S13 (female) (1), J13, J11, and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C02 (female) (16), J19, and S12 (female) (2) or between C02 (female) (16) and S13 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 5 harness Between wiring harness between C02 (female) (16), (Contact with 24 V circuit) J19, and S12 (female) (2) or between C02 (female) (16) Voltage Below 1 V and S13 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 6 Pump controller defective
20-548 (1)
C02
Left travel lever
Voltage
Between (16) and grounding
Neutral
20 – 30 V
Forward or reverse
Below 1 V
PC750, 800-7
TROUBLESHOOTING
E-26
Circuit diagram related to left travel forward PPC oil pressure switch and left travel reverse PPC oil pressure switch
PC750, 800-7
20-549 (1)
TROUBLESHOOTING
E-27
E-27 "Right travel" is not displayed normally in monitoring function Failure information
• "Right travel" is not displayed normally in monitoring function
"Right travel" is not displayed normally in the monitoring function (special function) of the monitor panel.
Relative information Cause Right travel forward PPC oil pressure switch 1 defective (Internal disconnection or short-circuiting)
Presumed cause and standard value in normalcy
Right travel reverse PPC oil pressure switch 2 defective (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S01 (male) Between (1) and (2)
Right travel lever
Resistance value
Neutral
Above 1 Mz
Forward
Below 1 z
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S11 (male) Between (1) and (2)
Right travel lever
Resistance value
Neutral
Above 1 Mz
Reverse
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Wiring harness between C03 (female) (39), J19, and S01 (female) (2) or between C03 (female) (39) and S11 (female) (2)
Resistance value
Below 1 z
Wiring harness between S01 (female) (1), J13, J11, and grounding
Resistance value
Below 1 z
Wiring harness between S11 (female) (1), J13, J11, and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (39), J19, and S01 (female) (2) or between C03 (female) (39) and S11 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 5 harness Between wiring harness between C03 (female) (39), (Contact with 24 V circuit) J19, and S01 (female) (2) or between C03 (female) (39) Voltage Below 1 V and S11 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 6 Pump controller defective
20-550 (1)
C02
Right travel lever
Voltage
Between (39) and grounding
Neutral
20 – 30 V
Forward or reverse
Below 1 V
PC750, 800-7
TROUBLESHOOTING
E-27
Circuit diagram related to right travel forward PPC oil pressure switch and right travel reverse PPC oil pressure switch
PC750, 800-7
20-551 (1)
TROUBLESHOOTING
E-28
E-28 "Service" is not correctly displayed in monitor function When attachment is installed Failure information
• "Service" is not correctly displayed in monitor "Service" is not correctly displayed in the monitor funcfunction tion (special function) on the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
Service PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S09 (male) Between (1) and (2)
Service pedal
Resistance value
NEUTRAL
Above 1 Mz
Operated
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (35) and S09 (female) (2)
Resistance value
Below 1 z
Wiring harness between S09 (female) (1) to J13 to J11 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (35) and S09 (female) (2)
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness (Contact with 24 V circuit) Wiring harness between C02 (female) (35) and S09 Voltage Below 1 V (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective
20-552 (1)
C02
Service pedal
Voltage
Between (35) and grounding
NEUTRAL
20 – 30 V
Operated
Below 1 V
PC750, 800-7
TROUBLESHOOTING
E-28
Electrical Circuit Diagram for Service PPC hydraulic Switch
PC750, 800-7
20-553 (1)
TROUBLESHOOTING
E-29
E-29 Air conditioner does not work Failure information
• The air conditioner does not work.
Relative information Cause
Presumed cause and standard value in normalcy
1 Fuse No. 11 fault Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
Standard value in normalcy and references for troubleshooting When fuse is blown, there is a big possibility that grounding fault occurred in the circuit. (See Cause 3.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between FB1-11 outlet and M26 (male) (4) (5)
Resistance value
Below 1 z
Wiring harness between M26 (male) (8) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-11 outlet and M26 (male) (4) (5) and grounding
Voltage
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4
Air conditioner unit defective
M26
Voltage
Between (4) (5) and (8)
20 – 30 V
If the above voltages are normal and the air conditioner does not operate, the air conditioner unit is defective.
Electrical Circuit Diagram for Air Conditioner
20-554 (1)
PC750, 800-7
TROUBLESHOOTING
E-30
E-30 Step light does not light up or go off Failure information
• The step light does not light up or go off.
(1) When the switch is pressed, the light does not keep lighting up for 1 minute.
Relative information Cause 1 Fuse No. 20 defective
If the fuse is broken, the circuit probably has grounding fault (See cause 7).
2 Step light defective
The step light may be defective. Check the bulb directly for breakage.
Step light switch 3 defective (Internal disconnection)
Step light power source 4 holding relay defective (Internal defect)
Presumed cause and standard value in normalcy
Standard value in normalcy and references for troubleshooting
Step light relay defective 5 (Internal defect)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M81 (male) Between (1) and (2)
Step light switch
Resistance value
Released
Above 1 Mz
Pressed
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Replace the step light power source holding relay with another one. If trouble is repaired, the relay is defective.
R14
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Replace the step light relay with another one. If trouble is repaired, the relay is defective.
R15
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Disconnection of wiring harness 6 (Disconnection or defective contact with connector)
PC750, 800-7
Wiring harness between FB1-20 outlet and M81 (female) (2) or between FB1-20 outlet and R14 (female) (3) or between FB1-20 outlet and R15 (female) (3)
Resistance value
Below 1 z
Wiring harness between M81 (female) (1), J07, and C01 (female) (24) or between M81 (female) (1), D04 and R14 (female) (1)
Resistance value
Below 1 z
Wiring harness between C03 (female) (5), D02, and R14 (female) (1)
Resistance value
Below 1 z
Wiring harness between R14 (female) (2), J04, J22, and grounding
Resistance value
Below 1 z
Wiring harness between R14 (female) (5), J07, and C03 (female) (1), (2), (11), (12), (14), and (24)
Resistance value
Below 1 z
Wiring harness between C03 (female) (15) and R15 (female) (1)
Resistance value
Below 1 z
Wiring harness between R15 (female) (2), J04, J22, and grounding
Resistance value
Below 1 z
Wiring harness between R15 (female) (5) and M75 (female) (1)
Resistance value
Below 1 z
Wiring harness between M75 (female) (2) and grounding
Resistance value
Below 1 z
20-555 (1)
TROUBLESHOOTING
Cause
E-30
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Presumed cause and standard value in normalcy
Grounding fault of wiring harness 7 (Contact with grounding circuit)
Pump controller defective (Step light switch input system)
Between wiring harness between FB1-20 outlet and M81 (female) (2) or between FB1-20 outlet and R14 (female) (3) or between FB1-20 outlet and R15 (female) (3) and grounding
Resistance value
Above 1 Mz
Between wiring harness between M81 (female) (1), J07, and C01 (female) (24) or between M81 (female) (1), D04 and R14 (female) (1) or between M81 (female) (1) and D02 (female) (4) and grounding
Resistance value
Above 1 Mz
Between wiring harness between R14 (female) (5), J07, and C03 (female) (1), (2), (11), (12), (14), and (24) and grounding
Resistance value
Above 1 Mz
Between wiring harness between R15 (female) (5), M75 (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C01
Step light switch
Voltage
Between (24) and grounding
Released
Below 1 V
Pressed
20 – 30 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Pump controller defective C03 (Step light power source 8 holding relay output system) Between (5) and grounding
Step light switch
Voltage
Released
Below 1 V
Pressed
20 – 30 V (60 seconds)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Pump controller defective (Step light relay output system)
20-556 (1)
C03 Between (15) and grounding
Step light switch
Voltage
Released
Below 1 V
Pressed
20 – 30 V (60 seconds)
PC750, 800-7
TROUBLESHOOTING
Failure information
E-30
• The step light does not light up or go off.
(2) While the switch is not pressed, the light lights up.
Relative information Cause Step light switch 1 defective (Internal disconnection)
Step light power source 2 holding relay defective (Internal defect)
Step light relay defective 3 (Internal defect)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M81 (male) Between (1) and (2)
Step light switch
Resistance value
Released
Above 1 Mz
Pressed
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Replace the step light power source holding relay with another one. If trouble is repaired, the relay is defective.
R14
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Replace the step light relay with another one. If trouble is repaired, the relay is defective.
R15
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between M81 (female) (1), J07, Short-circuiting of wiring and C01 (female) (24) or between M81 (female) (1), D04, and R14 (female) (1) and grounding 4 harness (Contact with 24 V circuit) Between wiring harness between C03 (female) (5), D02, and R14 (female) (1) and grounding Between wiring harness between C03 (female) (15) and R15 (female) (1) Pump controller defective (Step light switch input system)
Voltage
Below 1 V
Voltage
Below 1 V
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C01
Step light switch
Voltage
Between (24) and grounding
Released
Below 1 V
Pressed
20 – 30 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Pump controller defective C03 (Step light power source 5 holding relay output system) Between (5) and grounding
Step light switch
Voltage
Released
Below 1 V
Pressed
20 – 30 V (60 seconds)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Pump controller defective (Step light relay output system)
PC750, 800-7
C03 Between (15) and grounding
Step light switch
Voltage
Released
Below 1 V
Pressed
20 – 30 V (60 seconds)
20-557 (1)
TROUBLESHOOTING
E-30
Circuit diagram related to step light
20-558 (1)
PC750, 800-7
TROUBLESHOOTING
E-31
E-31 Electric grease gun does not operate Failure information
• The electric grease gun does not operate.
Relative information Cause 1
Circuit breaker No. 3 defective
Presumed cause and standard value in normalcy
Grease gun remote 2 switch defective (Internal disconnection)
If the circuit breaker is turned OFF, the circuit probably has grounding fault (See cause 4). a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. G12 (female) Between (1) and (2)
Remote switch
Resistance value
OFF
Above 1 Mz
ON
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
5 Grease pump defective
20-560 (1)
Standard value in normalcy and references for troubleshooting
Wiring harness between B23 and G12 (male) (1)
Resistance value
Below 1 z
Wiring harness between G12 (male) (2) and G11 (male) (1)
Resistance value
Below 1 z
Wiring harness between G11 (male) (2) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between B23 and G12 (male) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between G12 (male) (2) and G11 (male) (1) and grounding
Resistance value
Above 1 Mz
If causes 1 – 4 are not detected, the grease pump may be defective. (Since trouble is in the grease pump, troubleshooting cannot be carried out.)
PC750, 800-7
TROUBLESHOOTING
E-31
Circuit diagram related to electric grease gun
PC750, 800-7
20-561 (1)
TROUBLESHOOTING
E-32
E-32 Travel alarm does not sound or does not stop sounding Failure information
• The travel alarm does not sound or does not stop sounding.
(1) The alarm does not sound while the machine is traveling. (2) The alarm sounds while the machine is stopped.
Relative information Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
1 Travel signal defective
Monitoring code
Item
Normal display
01901 Pressure switch 2
Left travel
Lever operated: ON Lever in neutral: OFF
01900 Pressure switch 1
Right travel
Lever operated: ON Lever in neutral: OFF
If the display on the monitor panel is abnormal, carry out troubleshooting in "*** is not displayed normally in monitoring function".
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. Travel alarm defective 2 (Internal defect)
F01 (female) Between (1) and (2)
Travel lever
Voltage
Neutral
Below 1 V
Operated
20 – 30 V
If the above voltages are normal and the travel alarm does not sound, the travel alarm is defective. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (8) and F01 (female) (1)
Resistance value
Below 1 z
Wiring harness between F01 (female) (2), J21, and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness (Contact with 24 V circuit) Between wiring harness between C03 (female) (8) and Voltage Below 1 V F01 (female) (1) and grounding a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 5 Pump controller defective
C03 Between (8) and grounding
20-562 (1)
Travel lever
Voltage
Neutral
Below 1 V
Operated
20 – 30 V
PC750, 800-7
TROUBLESHOOTING
E-32
Circuit diagram related to travel alarm
PC750, 800-7
20-563 (1)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)............. 20-602 INFORMATION IN TROUBLESHOOTING TABLE ..................................................................................... 20-607 H-1 Speed or power of all work equipment, travel, and swing is low .......................................................... 20-608 H-2 Engine speed lowers remarkably or engine stalls ................................................................................ 20-610 H-3 All work equipment, travel, and swing systems do not work ................................................................ 20- 611 H-4 Abnormal sound is heard from around pump ....................................................................................... 20-612 H-5 Boom speed or power is low ................................................................................................................ 20-613 H-6 Speed or power of arm is low............................................................................................................... 20-615 H-7 Speed or power of bucket is low .......................................................................................................... 20-616 H-8 Boom does not move ........................................................................................................................... 20-617 H-9 Arm does not move .............................................................................................................................. 20-617 H-10 Bucket does not move........................................................................................................................ 20-617 H-11 Hydraulic drift of work equipment is large........................................................................................... 20-618 H-12 Time lag of work equipment is large................................................................................................... 20-620 H-13 Heavy lift function does not operate or stop ....................................................................................... 20-621 H-14 Machine push-up function does not operate or stop .......................................................................... 20-621 H-15 Boom shockless function cannot be turned ON or OFF..................................................................... 20-621 H-16 Machine deviates in one direction ...................................................................................................... 20-622 H-17 Machine deviates largely at start........................................................................................................ 20-624 H-18 Machine deviates largely during compound operation ....................................................................... 20-625 H-19 Travel speed or power is low.............................................................................................................. 20-625 H-20 Machine does not travel (only one track) ........................................................................................... 20-626 H-21 Travel speed does not change ........................................................................................................... 20-627 H-22 Upper structure does not swing ......................................................................................................... 20-628 H-23 Swing speed or acceleration is low .................................................................................................... 20-629 H-24 Swing speed or acceleration is low during compound operation of swing and work equipment........ 20-630 H-25 Upper structure overruns excessively when it stops swinging ........................................................... 20-632 H-26 Large shock is made when upper structure stops swinging............................................................... 20-633 H-27 Large abnormal sound is made when upper structure stops swinging .............................................. 20-634 H-28 Hydraulic drift of swing is large .......................................................................................................... 20-635
PC750, 800-7
20-601 (1)
TROUBLESHOOTING
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
20-602 (1)
PC750, 800-7
TROUBLESHOOTING
1. Combination and operation of hydraulic pumps • For the work equipment, travel, and swing circuits, 2 tandem pumps (4 pump units) of the No. 1 pump (HPV95+95) and the No. 2 pump (HPV95+95) are used. • The oil from the No. 1 front pump and that from the No. 2 front pump merge together and flow in the left 5-spool valve. The oil from the No. 1 rear pump and that from the No. 2 rear pump merge together and flow in the right 4-spool valve. • The TVC valve installed on the No. 1 rear pump carries out the TVC control of the No. 1 pump and No. 2 pump similarly. • The CO-NC valve installed on the No. 1 front pump and the jet sensor installed to the left 5-spool valve carry out the CO-NC control of the No. 1 front pump and No. 2 front pump similarly. • The CO-NC valve installed on the No. 1 rear pump and the jet sensor installed to the right 4-spool valve carry out the CO-NC control of the No. 1 rear pump and No. 2 rear pump similarly.
PC750, 800-7
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
2. Finding cause of trouble that "work equipment speed is low and machine deviates to left" • The possible causes of this trouble are as follows: 1) The main relief valve of the left 5-spool valve is defective. 2) The jet sensor of the left 5-spool valve is defective. 3) The CO-NC valve of the No. 1 front pump is defective. 4) The servo valve of the No. 1 front pump is defective. 5) The No. 1 front pump is defective. 6) The servo valve of the No. 2 front pump is defective. 7) The No. 2 front pump is defective. • Whether the main relief valve, jet sensor, and CO-NC valve are good or not can be judged by measuring the relief pressure, differential pressure, and output pressure respectively. • Since the oil from the No. 1 front pump and that from the No. 2 front pump merge together as explained in 1 above, exchange the outlet hoses of the No. 2 front and rear pumps and check the phenomenon of the machine to find out a defective system in the servo valves and pump units of the No. 1 and No. 2 front pumps. 1) If the machine still deviates to the left (If deviation does not change), the No. 1 front pump system is defective. 2) If the machine deviates to the right (If deviation changes), the No. 2 front pump system is defective. 3) If the travel speed lowers, the jet sensor or the CO-NC valve is defective (when the right and left relief pressures are normal). • To judge the condition of the servo valve and pump unit, remove the servo valve and test it or measure the stroke of the servo piston. a Actually, judge the condition according "4. Judgment matrix for trouble that work equipment speed is low and machine deviates".
20-603 (1)
TROUBLESHOOTING
3. Finding cause of trouble that "work equipment speed is low and machine deviates to right" • The possible causes of this trouble are as follows: 1) The main relief valve of the right 4-spool valve is defective. 2) The jet sensor of the right 4-spool valve is defective. 3) The CO-NC valve of the No. 1 rear pump is defective. 4) The servo valve of the No. 1 rear pump is defective. 5) The No. 1 rear pump is defective. 6) The servo valve of the No. 2 rear pump is defective. 7) The No. 2 rear pump is defective. • Whether the main relief valve, jet sensor, and CO-NC valve are good or not can be judged by measuring the relief pressure, differential pressure, and output pressure respectively. • Since the oil from the No. 1 rear pump and that from the No. 2 rear pump merge together as explained in 1 above, exchange the outlet hoses of the No. 2 front and rear pumps and check the phenomenon of the machine to find out a defective system in the servo valves and pump units of the No. 1 and No. 2 rear pumps. 1) If the machine still deviates to the left (If deviation does not change), the No. 1 rear pump system is defective. 2) If the machine deviates to the right (If deviation changes), the No. 2 rear pump system is defective. 3) If the travel speed lowers, the jet sensor or the CO-NC valve is defective (when the right and left relief pressures are normal). • To judge the condition of the servo valve and pump unit, remove the servo valve and test it or measure the stroke of the servo piston. a Actually, judge the condition according "4. Judgment matrix for trouble that work equipment speed is low and machine deviates".
20-604 (1)
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
4. Judgment matrix for trouble that work equipment speed is low and machine deviates (on the next page) a Carry out diagnosis in order from the top line and judge the factor having the most black points (q) to be the cause of the trouble. 1) To judge the servo valve, remove it and test it or measure the stroke of the servo piston. a Perform the test on the servo piston unit in the specified maintenance shop. 2) If the speed lowers extremely and the pump seems to be abnormal, check the line filter too. 3) If the speed lowers little but cannot be set to the normal level by adjusting each device, check the line filter too. 4) To check the operation of the servo piston, remove the caps from both sides of it and move the servo piston with the hand.
PC750, 800-7
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
TROUBLESHOOTING
Causes No. 1 pump
Pump unit defective
CO-NC valve defective
Servo valve defective
Pump unit defective
Servo valve defective
Pump unit defective
Servo valve defective
Pump unit defective
Main relief valve defective
Jet sensor defective
Main relief valve defective
Jet sensor defective
Left travel motor
Right travel motor
Diagnosis
Rear pump
Rear pump
Servo valve defective
Remedy No.
Front pump
Front pump CO-NC valve defective
Remedy A: Adjust Remedy X: Repair or replace
Left Right 5-spool 4-spool valve valve
No. 2 pump
A X
X
X
A X
X
X
X
X
X
X
A X
A X
A X
A X
X
X
Machine "deviates to left" and work equipment speed and swing speed are low.
q q q
q q
q q
2
Machine "deviates to left" and single swing speed is particularly low.
q q q
q q
q
3
Machine "deviates to left" and single swing speed is normal.
4
Travel relief pressure of front pump circuit is low.
5 6 7 8
Machine "deviates to left"
1
When result of 4 is normal, exchange front and rear outlet hoses of No. 2 pump.
q q
Machine "deviates to left" (Deviation does not change).
q q
q
Machine "deviates to right" (Deviation changes). Speed of both travel motors is low.
q q q
When phenomenon of 5 occurs, servo valve of No. 1 front pump is normal.
q q
When phenomenon of 6 occurs, servo valve of No. 2 front pump is normal.
10
When phenomenon of 7 occurs, jet sensor differential pressure of left 5-spool valve is abnormal.
11
When result of 10 is normal, No. 1 front NC valve output pressure is abnormal.
12
Machine "deviates to right" and work equipment speed is low.
q q q
q q
q q
13
Machine "deviates to right" and bucket dump speed is particularly low.
q q q
q q
q
14
Machine "deviates to right" and bucket dump speed is normal.
15
Travel relief pressure of rear pump circuit is low.
16 17 18 19
Machine "deviates to right"
9
When result of 15 is normal, exchange front and rear outlet hoses of No. 2 pump.
q q q
q q
Machine "deviates to right" (Deviation does not change).
q q
Machine "deviates to left" (Deviation changes). Speed of both travel motors is low.
q q q
When phenomenon of 16 occurs, servo valve of No. 1 rear pump is normal.
20
When phenomenon of 17 occurs, servo valve of No. 2 rear pump is normal.
21
When phenomenon of 18 occurs, jet sensor differential pressure of right 4-spool valve is abnormal.
22
When result of 18 is normal, No. 1 front NC valve output pressure is abnormal.
PC750, 800-7
q
q q q q
20-605 (1)
TROUBLESHOOTING
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
How to exchange outlet hoses of No. 2 pump and hydraulic circuit diagram after they are exchanged
20-606 (1)
PC750, 800-7
TROUBLESHOOTING
INFORMATION IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE a Tables and related circuit diagrams concerning troubleshooting contains the following information. Please understand the contents sufficiently before carrying out troubleshooting. Failure Phenomenon
Phenomena on machine
Related Information
Information concerning to failure or troubleshooting. Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
1
2 Possible causes of failure
(The sequence number is • Standard values for judgement of possible causes. only for reference and • Remarks for judgement does not state priority.) 3
4
PC750, 800-7
20-607 (1)
TROUBLESHOOTING
H-1
H-1 Speed or power of all work equipment, travel, and swing is low Failure information
• Speed or power of all work equipment, travel, and swing is low
Relative information
• Measure the speed of the work equipment, travel, and swing speed and check that all of them are slow (or their power is low). • Check that abnormal sound is not heard from around the pump. (If abnormal sound is heard, carry out the related troubleshooting.) • Check that the machine does not deviate. (If the machine deviates, carry out the related troubleshooting.) • Carry out all the troubleshooting in working mode A. Cause
Standard value in normalcy and references for troubleshooting a Run the engine at high idling during troubleshooting.
1 Engine unit defective
PTO defective internally 2 (Control pump drive system) 3
Control pump defective internally
Heavy lift switch and right work equipment control lever
Engine speed
Heavy lift switch OFF + Boom RAISE relief
Above 1,700 rpm
Heavy lift switch ON + Boom RAISE relief
Above 1,700 rpm
a Keep the engine stopped for the preparations and troubleshooting. Disconnect the control pump outlet hose and rotate the crankshaft. If oil flows out of the pump outlet, PTO is normal. Control pump may be defective internally. Check inside of pilot filter for metal dust, etc. a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
Presumed cause and standard value in normalcy
Control levers Wrong adjustment or 4 malfunction of control relief valve
All levers in neutral
Control relief pressure +0.49 MPa 0 +5 {34 0 kg/cm2}
3.33
If the oil pressure is still abnormal after adjustment, check cause 5. If cause 5 is not detected, the control relief valve operation may be defective. Check the control relief valve directly. a Stop the engine and block (1) – (9) in Fig. 1 in order. Run the engine at high idling and check. 5
Leakage in control system devices
Control levers All levers in neutral
Control relief pressure +0.49 MPa 0 +5 {34 0 kg/cm2}
3.33
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Heavy lift switch and right work equipment control lever Wrong adjustment or 6 malfunction of main relief valve
Heavy lift switch OFF + Boom RAISE relief Heavy lift switch ON + Boom RAISE relief
Main relief pressure +1.0
31.4 –2.0 MPa +10
{320 –20 kg/cm2} +1.0
33.8 –2.0 MPa +10
{345 –20 kg/cm2}
If the oil pressure is still abnormal after adjustment, the main relief valve (on the lowpressure set side and high-pressure set side) may be defective. Check the main relief valve directly.
20-608 (1)
PC750, 800-7
TROUBLESHOOTING
Cause
H-1
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting (Start troubleshooting after checking that causes 4 and 6 are not detected).
7
Wrong adjustment or malfunction of TVC valve
Heavy lift switch and right work equipment control lever
TVC valve output pressure
All levers in neutral
Min. 1.76 MPa {Min. 18 kg/cm2}
Heavy lift switch OFF + Boom RAISE relief
1.18 ± 0.2 MPa {12 ± 2 kg/cm2}
Heavy lift switch ON + Boom RAISE relief
1.14 ± 0.2 MPa {11.6 ± 2 kg/cm2}
If the oil pressure is still abnormal after adjustment, the TVC valve may be defective. Check the TVC valve directly. a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. 8
Malfunction of CO cancel solenoid valve
Working mode
Solenoid valve outlet pressure
A-mode
Min. 2.74 MPa {Min. 28 kg/cm2}
E-mode
0 MPa {0 kg/cm2}
Fig. 1: Control system devices
PC750, 800-7
20-609 (1)
TROUBLESHOOTING
H-2
H-2 Engine speed lowers remarkably or engine stalls Failure Phenomenon
• Engine speed lowers remarkably or engine stalls
Related Information
• Carry out all the troubleshooting in working mode A. Cause
Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling.
Presumed cause and standard value in normalcy
Defective adjustment or 1 malfunction of TVC valve
Heavy lift switch R.H. work equipment control lever
TVC valve output pressure
All control levers in neutral
Min. 1.76 MPa {Min. 18 kg/cm2}
Heavy lift switch OFF + Boom relieved in RAISE position
1.18 ± 0.2 MPa {12 ± 2 kg/cm2}
Heavy lift switch ON + Boom relieved in RAISE position
1.14 ± 0.2 MPa {11.6 ± 2 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the TVC valve may have a malfunction. Check the TVC valve directly. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. (Check cause 1 and confirm that the result is normal before troubleshooting.) Defective adjustment or 2 malfunction of CO • NC valve
Heavy lift switch R.H. work equipment control lever
CO • NC valve output pressure
Heavy lift switch OFF + Boom relieved in RAISE position
1.18 ± 0.2 MPa {12 ± 2 kg/cm2}
Heavy lift switch ON + Boom relieved in RAISE position
1.14 ± 0.2 MPa {11.6 ± 2 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the CO • NC valve may have a malfunction. Check the CO • NC valve directly. 3 Defective engine
20-610 (1)
If the results of check of causes 1 and 2 are normal, the engine may be defective. Check the engine
PC750, 800-7
TROUBLESHOOTING
H-3
H-3 All work equipment, travel, and swing systems do not work Failure information
• All work equipment, travel, and swing systems do not work
Relative information
• Carry out all the troubleshooting in working mode A. Cause
PTO defective internally 1 (Main pump drive system)
a Keep the engine stopped for the preparations and troubleshooting.
PTO defective internally 2 (Control pump drive system)
a Keep the engine stopped for the preparations and troubleshooting.
3
Presumed cause and standard value in normalcy
Standard value in normalcy and references for troubleshooting
Control pump defective internally
Disconnect the main pump oil pressure pickup coupler and rotate the crankshaft. If oil flows out of the pump outlet, PTO is normal. Disconnect the control pump outlet hose and rotate the crankshaft. If oil flows out of the pump outlet, PTO is normal. Control pump may be defective internally. Check inside of pilot filter for metal dust, etc. a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Control levers
Wrong adjustment or 4 malfunction of control relief valve
All levers in neutral
Control relief pressure +0.49 MPa 0 +5 {34 0 kg/cm2}
3.33
If the oil pressure is still abnormal after adjustment, check cause 5. If cause 5 is not detected, the control relief valve operation may be defective. Check the control relief valve directly. a Stop the engine and block (1) – (9) in Fig. 1 in order. Run the engine at high idling and check. 5
Leakage in control system devices
Control levers All levers in neutral
Control relief pressure 3.33 {34
+0.49 0
+5 0
MPa
kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. 6
Malfunction of PPC lock solenoid valve
PC750, 800-7
Safety lock lever
Solenoid valve outlet pressure
FREE
Min. 2.74 MPa {28 kg/cm2}
LOCK
0 MPa {0 kg/cm2}
20-611 (1)
TROUBLESHOOTING
H-3, H-4
Fig. 1: Control system devices
H-4 Abnormal sound is heard from around pump Failure Phenomenon
• Abnormal sound is heard from around pump
Presumed cause and standard value in normalcy
Related Information Cause 1 Low hydraulic oil level
Since the hydraulic oil level may be low, check it directly.
2 Loosened piping clamp
Since a piping clamp between the hydraulic tank and hydraulic pump may be loosened, check it directly.
3
Clogged hydraulic tank strainer
4
Internal defect of hydrauSince the hydraulic pump may have a defect in it, check it directly. lic pump
5 Observation of condition
20-612 (1)
Standard value in normalcy and references for troubleshooting
Since the hydraulic tank strainer may be clogged, check it directly.
If a cause cannot be found by troubleshooting, operate the machine as it is for a while and observe the condition for change.
PC750, 800-7
TROUBLESHOOTING
H-5
H-5 Boom speed or power is low Failure information
• Boom speed or power is low
Relative information
• The normal mode is the state that the heavy lift switch, swing priority switch, and machine push-up switch are turned OFF. • Check that the other work equipment, travel, and swing are normal. (If any of them is abnormal, carry out troubleshooting related to it.) • Check that the machine does not deviate. (If it deviates, carry out troubleshooting related to deviation.) • When carrying out the following troubleshooting, set the working mode in the A-mode. Cause
1
Malfunction of right PPC valve (Boom circuit)
(1) The boom speed or power is low in the normal mode.
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Right work equipment control lever
PPC valve output pressure
Boom RAISE/LOWER stroke end
Min. 2.74 MPa {Min. 28 kg/cm2}
Presumed cause and standard value in normalcy
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Malfunction of swing 2 priority solenoid valve
3
Malfunction of boom control valve (spool)
Swing priority switch and right work equipment control lever
Solenoid valve outlet pressure
Swing priority switch OFF + Lever in neutral
0 MPa {0 kg/cm2}
Swing priority switch ON + Boom RAISE operation
Min. 2.74 MPa {Min. 28 kg/cm2}
The spool of the boom control valve (Lo, Hi) may malfunction. Check it directly.
Malfunction of boom 4 control valve (Safety-suction valve)
The safety-suction valve of the boom control valve (Lo) may malfunction. Check it directly. (When checking the safety-suction valve by exchanging it with a valve of another work equipment circuit, stop the hose of the machine push-up solenoid securely. After finishing check, be sure to return the safety-suction valve since its set pressure and structure are different from others.)
Boom control valve 5 (control valve unit) defective
The control valve unit of the boom control valve (Lo, Hi) may be defective. Check it directly.
6
Boom cylinder seal defective
PC750, 800-7
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Right work equipment control lever
Leakage from cylinder
Boom RAISE relief
Max. 20 cc/min
20-613 (1)
TROUBLESHOOTING
H-5
Failure information
• Boom speed or power is low
Relative information
• The heavy lift mode is the state that the heavy lift switch is turned ON. • Check that the other work equipment, travel, and swing are normal. (If any of them is abnormal, carry out troubleshooting related to it.) • Check that the machine does not deviate. (If it deviates, carry out troubleshooting related to deviation.) • When carrying out the following troubleshooting, set the working mode in the A-mode. Cause
(2) The boom raise speed or power is low in the heavy lift mode.
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
Presumed cause and standard value in normalcy
1
Malfunction of CO cancel solenoid valve
Right work equipment control lever
Solenoid valve outlet pressure
Neutral
0 MPa {0 kg/cm2}
Single boom RAISE operation
Min. 2.74 MPa {Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. 2
Malfunction of 2-stage relief solenoid valve
Right work equipment control lever
Solenoid valve outlet pressure
Neutral
0 MPa {0 kg/cm2}
Single boom RAISE operation
Min. 2.74 MPa {Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Wrong adjustment or 3 malfunction of main relief valve
Right work equipment control lever
Main relief pressure +1.0
Single boom RAISE operation
33.8 –2.0 MPa +10
{345 –20 kg/cm2}
If the main relief valve is still abnormal after adjustment, its operation (on the high pressure set side) may be defective. Check it directly.
Failure information
• Boom speed or power is low
Relative information
• The heavy lift mode is the state that the machine push-up switch is turned ON. • Check that the other work equipment, travel, and swing are normal. (If any of them is abnormal, carry out troubleshooting related to it.) • Check that the machine does not deviate. (If it deviates, carry out troubleshooting related to deviation.) • When carrying out the following troubleshooting, set the working mode in the A-mode.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
1
Malfunction of machine push-up solenoid valve
Malfunction of boom 2 control valve (Safety-suction valve)
20-614 (1)
(3) The boom lower speed or power is low in the machine push-up mode.
Machine push-up switch
Solenoid valve outlet pressure
OFF
Min. 2.74 MPa {Min. 28 kg/cm2}
ON
0 MPa {0 kg/cm2}
The safety-suction valve of the boom control valve (Lo) (on the high pressure set side on the head side) may malfunction. Check it directly.
PC750, 800-7
TROUBLESHOOTING
H-6
H-6 Speed or power of arm is low Failure Phenomenon
• Speed or power of arm is low
Related Information
• Check that the speeds of the other work equipment, travel, and swing are normal. (If they are abnormal, carry out the related troubleshooting.) • Check that the machine does not deviate. (If the machine deviates, carry out the related troubleshooting.) • Carry out all the troubleshooting in working mode A. Cause
Presumed cause and standard value in normalcy
1
2
Malfunction of left PPC valve (arm circuit)
Malfunction of arm control valve (spool)
Malfunction of arm 3 control valve (safety & suction valve) 4
5
Defective arm control valve (body) Defective seal of arm cylinder
PC750, 800-7
Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. L.H. work equipment control lever
PPC valve output pressure
Arm IN, OUT Full stroke
Min. 2.74 MPa {Min. 28 kg/cm2}
Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it directly. The safety-suction valve of the arm control valve (Lo, Hi) may malfunction. Check it directly. (After checking the safety-suction valve by exchanging it with a valve of another work equipment circuit, be sure to return it since its set pressure is different from others.) Since the body of the arm control valve (Lo, Hi) may have a malfunction, check it directly. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. L.H. work equipment control lever
Leakage from cylinder
Relieved in arm IN position
Max. 20 cc/min
20-615 (1)
TROUBLESHOOTING
H-7
H-7 Speed or power of bucket is low Failure Phenomenon
• Speed or power of bucket is low
Related Information
• Check that the speeds of the other work equipment, travel, and swing are normal. (If they are abnormal, carry out the related troubleshooting.) • Check that the machine does not deviate. (If the machine deviates, carry out the related troubleshooting.) • Carry out all the troubleshooting in working mode A. Cause
Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling.
Presumed cause and standard value in normalcy
1
2
Malfunction of bucket control valve (spool)
Malfunction of bucket 3 control valve (safety & suction valve) 4
5
20-616 (1)
Malfunction of right PPC valve (bucket circuit)
Defective bucket control valve (body)
Defective seal of bucket cylinder
R.H. work equipment control lever (bucket)
PPC valve output pressure
Bucket CURL, DUMP Full stroke
Min. 2.74 MPa {Min. 28 kg/cm2}
Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it directly. Since the safety & suction valve of the bucket control valve (Lo, Hi) may have a malfunction, check it directly. (The safety & suction valve may be checked by replacing it with one of another work equipment circuit. After checking, however, be sure to return the safety & suction valve since its set pressure and structure are different from the others.) Since the body of the bucket control valve (Lo, Hi) may have a malfunction, check it directly. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. R.H. work equipment control lever (bucket)
Leakage from cylinder
Relieved in bucket CURL position
Max. 20 cc/min
PC750, 800-7
TROUBLESHOOTING
H-8, H-9, H-10
H-8 Boom does not move • Boom does not move
Related Information
• Check that operations of the other work equipment, travel, and swing are normal. (If they are abnormal, carry out the related troubleshooting.) • Carry out all the troubleshooting in working mode A.
Presumed cause and standard value in normalcy
Failure Phenomenon
Cause Malfunction of right PPC 1 valve (boom circuit)
2
Malfunction of boom control valve (spool)
Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. R.H. work equipment control lever
PPC valve output pressure
Boom RAISE, LOWER Full stroke
Min. 2.74 MPa {Min. 28 kg/cm2}
Since the spool of the boom control valve (Lo, Hi) may have a malfunction, check it directly.
H-9 Arm does not move • Arm does not move
Related Information
• Check that operations of the other work equipment, travel, and swing are normal. (If they are abnormal, carry out the related troubleshooting.) • Carry out all the troubleshooting in working mode A.
Presumed cause and standard value in normalcy
Failure Phenomenon
Cause
1
2
Malfunction of left PPC valve (arm circuit)
Malfunction of arm control valve (spool)
Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. L.H. work equipment control lever
PPC valve output pressure
Arm IN, OUT Full stroke
Min. 2.74 MPa {Min. 28 kg/cm2}
Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it directly.
H-10 Bucket does not move • Bucket does not move
Related Information
• Check that operations of the other work equipment, travel, and swing are normal. (If they are abnormal, carry out the related troubleshooting.) • Carry out all the troubleshooting in working mode A.
Presumed cause and standard value in normalcy
Failure Phenomenon
Cause
1
2
Malfunction of right PPC valve (bucket circuit)
Malfunction of bucket control valve (spool)
PC750, 800-7
Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. R.H. work equipment control lever
PPC valve output pressure
Bucket CURL, DUMP Full stroke
Min. 2.74 MPa {Min. 28 kg/cm2}
Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it directly.
20-617 (1)
TROUBLESHOOTING
H-11
H-11 Hydraulic drift of work equipment is large Failure Phenomenon
• Hydraulic drift of work equipment is large
(1) Hydraulic drift of boom is large
Related Information
Presumed cause and standard value in normalcy
Cause 1
Defective seal of boom control valve (spool)
Standard value in normalcy and references for troubleshooting Since the spool of the boom control valve (Lo) may have a malfunction, check it directly.
Since the safety & suction valve (bottom side) of the boom control valve (Lo) may have Malfunction of boom con- a malfunction, check it directly. (The safety & suction valve may be checked by replac2 trol valve (safety & sucing it with one of another work equipment circuit. After checking, however, be sure to tion valve) return the safety & suction valve since its set pressure and structure are different from the others.)
3
Defective seal of boom cylinder
Failure Phenomenon
a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. R.H. work equipment control lever
Leakage from cylinder
Relieved in boom RAISE position
Max. 20 cc/min
• Hydraulic drift of work equipment is large
(2) Hydraulic drift of arm is large
Related Information
Presumed cause and standard value in normalcy
Cause 1
Malfunction of arm 2 control valve (safety & suction valve)
3
20-618 (1)
Defective seal of arm control valve (spool)
Defective seal of arm cylinder
Standard value in normalcy and references for troubleshooting Since the spool of the arm control valve (Lo) may have a malfunction, check it directly. Since the safety & suction valve (head side) of the arm control valve (Lo) may have a malfunction, check it directly. (The safety & suction valve may be checked by replacing it with one of another work equipment circuit. After checking, however, be sure to return the safety & suction valve since its set pressure and structure are different from the others.) a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. L.H. work equipment control lever
Leakage from cylinder
Relieved in arm IN position
Max. 20 cc/min
PC750, 800-7
TROUBLESHOOTING
Failure Phenomenon
H-11
• Hydraulic drift of work equipment is large
(3) Hydraulic drift of bucket is large
Presumed cause and standard value in normalcy
Related Information Cause
Standard value in normalcy and references for troubleshooting
Defective seal of bucket 1 control valve (spool)
Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it directly.
Malfunction of bucket 2 control valve (safety & suction valve)
Since the safety & suction valve (bottom side) of the bucket control valve (Lo, Hi) may have a malfunction, check it directly. (The safety & suction valve may be checked by replacing it with one of another work equipment circuit. After checking, however, be sure to return the safety & suction valve since its set pressure and structure are different from the others.)
Defective seal of bucket 3 cylinder
PC750, 800-7
a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. R.H. work equipment control lever
Leakage from cylinder
Relieved in bucket CURL position
Max. 20 cc/min
20-619 (1)
TROUBLESHOOTING
H-12
H-12 Time lag of work equipment is large Failure Phenomenon
• Time lag of work equipment is large
(1) Time lag of boom is large
Related Information Cause Presumed cause and standard value in normalcy
Failure Phenomenon
1
Malfunction of boom control valve (safety & suction valve)
Standard value in normalcy and references for troubleshooting Since the safety & suction valve (head side) of the boom control valve (Lo) may have a malfunction, check it directly. (When checking by replacing the safety & suction valve with one of another work equipment circuit, stop the oil in the machine pushup solenoid hose securely. After checking, be sure to return the safety & suction valve since its set pressure and structure are different from the others.)
• Time lag of work equipment is large
(2) Time lag of arm is large
Related Information Cause Presumed cause and standard value in normalcy
Failure Phenomenon
1
Malfunction of arm control valve (safety & suction valve)
Standard value in normalcy and references for troubleshooting Since the safety & suction valve (bottom side) of the arm control valve (Lo, Hi) may have a malfunction, check it directly. (The safety & suction valve may be checked by replacing it with one of another work equipment circuit. After checking, however, be sure to return the safety & suction valve since its set pressure and structure are different from the others.)
• Time lag of work equipment is large
(3) Time lag of bucket is large
Related Information Cause Presumed cause and standard value in normalcy
20-620 (1)
1
Standard value in normalcy and references for troubleshooting
Since the safety & suction valve (bottom side) of the bucket control valve (Lo, Malfunction of bucket Hi) may have a malfunction, check it directly. (The safety & suction valve may control valve (safety be checked by replacing it with one of another work equipment circuit. After checking, however, be sure to return the safety & suction valve since its set & suction valve) pressure and structure are different from the others.)
PC750, 800-7
TROUBLESHOOTING
H-13, H-14, H-15
H-13 Heavy lift function does not operate or stop Failure Phenomenon
• Heavy lift function does not operate or stop
Related Information Presumed cause and standard value in normalcy
Cause 1
Standard value in normalcy and references for troubleshooting Check by (2) in "H-5 Boom speed or power is low".
H-14 Machine push-up function does not operate or stop Failure Phenomenon
• Machine push-up function does not operate or stop
Related Information Presumed cause and standard value in normalcy
Cause 1
Standard value in normalcy and references for troubleshooting Check by (3) in "H-5 Boom speed or power is low".
H-15 Boom shockless function cannot be turned ON or OFF Failure Phenomenon
• Boom shockless function cannot be turned ON or OFF
Related Information Cause Presumed cause and standard value in normalcy
PC750, 800-7
1
Malfunction of boom shockless solenoid valve
2
Malfunction of boom shockless valve
Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting with the starting switch ON. Remove the solenoid valve from the valve assembly and connect the connector and operate the boom shockless control switch. If the spool moves at this time, the solenoid valve is normal. Since the boom shockless valve may have a malfunction, check it directly.
20-621 (1)
TROUBLESHOOTING
H-16
H-16 Machine deviates in one direction Failure Phenomenon
• Machine deviates in one direction
Related Information
• Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.) • Carry out all the troubleshooting in working mode A.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
1
Troubleshooting with judgment matrix
Carry out troubleshooting by using the judgment matrix in BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS. (H mode)
2
Wrong adjustment of main pump
See TESTING AND ADJUSTING, Testing and adjusting travel deviation.
3
Malfunction of travel PPC valve
a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. Travel lever
PPC valve output pressure
FORWARD, REVERSE Full stroke
2.74 MPa {28 kg/cm2}
4
Malfunction of travel control valve (spool)
Since the spool of the travel control valve may have a malfunction, check it directly.
5
Defective travel control valve (body)
Since the body of the travel control valve may have a malfunction, check it directly. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling.
6
Defective seal of center swivel joint
Travel lever
Leakage from swivel joint
Relieved on one side
Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 1.
7 Leakage in travel motor
8 Defective travel motor 9
20-622 (1)
(1) Machine deviates in the same direction, regardless of its travel direction
Internal defect of final drive
a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. Travel lever
Leakage from travel motor
Relieved on one side
Max. 40 l/min
Since the travel motor may be defective, check it directly. Since the final drive may have a defect in it, check it directly. (The defect can be judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.)
PC750, 800-7
TROUBLESHOOTING
H-16
Failure Phenomenon
• Machine deviates in one direction
Related Information
• Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.) • Carry out all the troubleshooting in working mode A. Cause
Presumed cause and standard value in normalcy
1
2
Malfunction of travel PPC valve
Malfunction of travel control valve (spool)
(2) Machine deviates in different directions, depending on its travel direction
Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. Travel lever
PPC valve output pressure
FORWARD, REVERSE Full stroke
2.74 MPa {28 kg/cm2}
Since the spool of the travel control valve may have a malfunction, check it directly. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling.
3
Defective seal of center swivel joint
Travel lever
Leakage from swivel joint
Relieved on one side
Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 1. a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. 4
Low set pressure of travel motor safety valve
Travel lever
Travel relief pressure +1.0
Relieved on one side
34.3 –2.0 MPa +10
{350 –20 kg/cm2}
Fig. 1 Defective seals in center swivel joint and travel deviation directions
PC750, 800-7
20-623 (1)
TROUBLESHOOTING
H-17
H-17 Machine deviates largely at start Failure Phenomenon
• Machine deviates largely at start
Related Information
• Check that the machine does not deviate during constant-speed travel. (If the machine deviates even during constant-speed travel, carry out the related troubleshooting.) • Carry out all the troubleshooting in working mode A.
Presumed cause and standard value in normalcy
Cause
(1) Machine deviates only when started with travel lever at full stroke
Standard value in normalcy and references for troubleshooting
1
Malfunction of main pump servo-valve
Since the servo-valve of main pumps (No. 1 & No. 2) may have a malfunction, check it directly. (Test the servo-valve unit or measure its stroke.)
2
Malfunction of travel control valve (spool)
Since the spool of the travel control valve may have a malfunction, check it directly.
Defective seal of center 3 swivel joint
4
Internal defect of travel motor (body)
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Travel lever
Leakage from swivel joint
Either side relief
Max. 100 cc/min
Since the travel motor may have a defect in it, check it directly.
Failure Phenomenon
• Machine deviates largely at start
Related Information
• Check that the machine does not deviate during constant-speed travel. (If the machine deviates even during constant-speed travel, carry out the related troubleshooting.) • Carry out all the troubleshooting in working mode A. Cause
(2) Machine deviates when started, regardless of travel lever stroke
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. (Check cause 3 and confirm that the result is normal before troubleshooting.) Defective adjustment or 1 malfunction of CO • NC valve
Travel lever
CO • NC valve output pressure
Neutral
Max. 0.55 MPa {Max. 5.5 kg/cm2}
Full stroke on one side (Idle travel)
Min. 1.67 MPa {Min. 17 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the CO • NC valve may have a malfunction or may be adjusted defectively. Check the CO • NC valve directly. 2
Malfunction of main pump servo-valve
Since the servo-valve of main pump may have a malfunction, check it directly. (Test the servo-valve unit or measure its stroke.) a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling.
3
Defective adjustment or malfunction of jet sensor
Travel lever
Differential pressure of jet sensor
Neutral
Min. 1.14 MPa {Min. 11.6 kg/cm2}
Full stroke on one side (Idle travel)
Max. 0.15 MPa {Max. 1.5 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the relief valve may have a malfunction or the orifice may be defective. Check the relief valve and orifice directly.
20-624 (1)
PC750, 800-7
TROUBLESHOOTING
H-18, H-19
H-18 Machine deviates largely during compound operation • Machine deviates largely during compound operation
Related Information
• Check that the machine does not deviate when the work equipment is not operated. (If the machine deviates under that condition, carry out the related troubleshooting.) • Carry out all the troubleshooting in working mode A.
Presumed cause and standard value in normalcy
Failure Phenomenon
Cause
Standard value in normalcy and references for troubleshooting Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling.
1
2
Control levers
Solenoid valve outlet pressure
All levers in neutral
0 MPa {0 kg/cm2}
Operation of work equipment or swing + Travel
Min. 2.74 MPa {Min. 28 kg/cm2}
Malfunction of travel junction solenoid valve
Malfunction of travel junction valve
Since the travel junction valve of the travel control valve may have a malfunction, check it directly.
H-19 Travel speed or power is low Failure Phenomenon
• Travel speed or power is low
Related Information
• Check that the machine does not deviate. (If the machine deviates, carry out the related troubleshooting.) • Carry out all the troubleshooting in working mode A. Cause
1
Malfunction of travel PPC valve
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Travel lever
PPC valve output pressure
Forward/Reverse stroke end
Min. 2.74 MPa {Min. 28 kg/cm2}
Presumed cause and standard value in normalcy
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. 2
Malfunction of CO cancel solenoid valve
Travel lever
Solenoid valve outlet pressure
Neutral
0 MPa {0 kg/cm2}
Operated
Min. 2.74 MPa {Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. 3
Malfunction of 2-stage relief solenoid valve
Travel lever
Solenoid valve outlet pressure
Neutral
0 MPa {0 kg/cm2}
Operated
Min. 2.74 MPa {Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Wrong adjustment or 4 malfunction of main relief valve
Travel lever
Travel relief pressure +1.0
Either side relieved
34.3 –2.0 MPa +10
{350 –20 kg/cm2}
If the main relief valve is still abnormal after adjustment, its operation (on the high pressure set side) may be defective. Check it directly.
PC750, 800-7
20-625 (1)
TROUBLESHOOTING
H-20
H-20 Machine does not travel (only one track) Failure Phenomenon
• Machine does not travel (only one track)
(1) Machine does not travel in either direction.
Presumed cause and standard value in normalcy
Related Information Cause
Standard value in normalcy and references for troubleshooting
1
Malfunction of travel motor (parking brake)
Since the parking brake of the travel motor may have a malfunction, check it directly.
2
Internal defect of travel motor (body)
Since the travel motor may have a defect in it, check it directly.
3
Internal defect of final drive
Since the final drive may have a defect in it, check it directly. (The defect can be judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.)
Failure Phenomenon
• Machine does not travel (only one track)
Related Information
• Carry out all the troubleshooting in working mode A. Cause
Presumed cause and standard value in normalcy
1
Malfunction of travel PPC valve
Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling. Travel levers
PPC valve output pressure
FORWARD, REVERSE Full stroke
Min. 2.74 MPa {Min. 28 kg/cm2}
2
Malfunction of travel control valve (spool)
Since the spool of the travel control valve may have a malfunction, check it directly.
3
Defective travel control valve (suction valve)
Since the suction valve of the travel control valve may have a malfunction, check it directly. (The suction valve can be checked by replacing it with normal one.) a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling.
4
Malfunction of travel motor (safety valve)
Malfunction of travel 5 motor (counterbalance valve)
20-626 (1)
(2) Machine does not travel forward or in reverse
Travel levers
Travel relief pressure
Relieved on one side (Direction in which machine does not travel)
34.3 –2.0 MPa
+1.0
+10
{350 –20 kg/cm2}
Since the counterbalance valve of the travel motor may have a malfunction, check it directly.
PC750, 800-7
TROUBLESHOOTING
H-21
H-21 Travel speed does not change • Travel speed does not change
Related Information
• Check that the Lo and Hi travel speeds are normal. (If they are abnormal, carry out the related troubleshooting.) • The travel speed selection system has the automatic speed changing function. If the oil pressure rises above 22.6 MPa {230 kg/cm2} during travel, the travel speed is changed to Lo even while the machine is traveling at Hi (Hi is still displayed on the monitor panel). • Carry out all the troubleshooting in working mode A.
Presumed cause and standard value in normalcy
Failure Phenomenon
Cause
Standard value in normalcy and references for troubleshooting a Prepare with the engine stopped, then carry out troubleshooting with the engine at high idling.
1
2
Malfunction of travel speed solenoid valve
Travel speed selection switch
Solenoid valve outlet pressure
Lo
0 MPa {0 kg/cm2}
Hi
Min. 2.74 MPa {Min.28 kg/cm2}
Malfunction of travel Since the servo mechanism of the travel motor may have a malfunction, check it motor (servo mechanism) directly.
PC750, 800-7
20-627 (1)
TROUBLESHOOTING
H-22
H-22 Upper structure does not swing Failure Phenomenon
• Upper structure does not swing
Related Information
• Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out troubleshooting related to it.) • When carrying out the following troubleshooting, set the swing lock switch in OFF and the working mode in the A-mode. Cause
(1) The upper structure swings in neither direction.
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
Presumed cause and standard value in normalcy
Malfunction of swing 1 holding brake solenoid valve
2
Malfunction of swing motor (parking brake)
Left work equipment control lever
Solenoid valve outlet pressure
Neutral (After 10 seconds or more)
0 MPa {0 kg/cm2}
Operated to swing (in either direction)
Min. 2.74 MPa {Min.28 kg/cm2}
The parking brake of the swing motor may malfunction. Check it directly. a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
Wrong adjustment or 3 malfunction of swing motor (safety valve)
Left work equipment control lever
Swing relief pressure
Swing relief (in either direction)
28.4 –0.5 MPa
+2.5
+25
{290 –5 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction. check the safety valve directly. 4
Swing motor (motor unit) defective internally
The motor unit of the swing motor may have a defect in it. Check it directly.
5
Swing machinery defective internally
Swing machinery may have a defect in it. Check it directly. (The swing machinery can be checked by abnormal sound, abnormal heating, metal dust in the drained oil, etc.)
Failure Phenomenon
• Upper structure does not swing
Related Information
• Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out troubleshooting related to it.) • When carrying out the following troubleshooting, set the swing lock switch in OFF and the working mode in the A-mode. Cause
Presumed cause and standard value in normalcy
1
2
Malfunction of swing control valve (spool)
Malfunction of swing 3 control valve (suction valve)
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Left work equipment control lever
PPC valve output pressure
Swing RIGHT/LEFT stroke end
Min. 2.74 MPa {Min.28 kg/cm2}
The spool of the swing control valve may malfunction. Check it directly. The suction valve of the swing control valve may malfunction. Check it directly. (The suction valves of the right and left swing control valves can be checked by exchanging them with each other and seeing the change of the phenomenon.)
4
Malfunction of swing motor (suction valve)
The suction valve of the swing motor may malfunction. Check it directly. (The suction valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
5
Malfunction of swing motor (check valve)
The check valve of the swing motor may malfunction. Check it directly. (The check valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
20-628 (1)
Malfunction of left PPC valve (swing circuit)
(2) The upper structure does not swing in only 1 direction.
PC750, 800-7
TROUBLESHOOTING
H-23
H-23 Swing speed or acceleration is low Failure Phenomenon
• Swing speed or acceleration is low
Related Information
• Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out troubleshooting related to it.) • When carrying out the following troubleshooting, set the working mode in the A-mode and turn the swing lock switch OFF. Cause
Presumed cause and standard value in normalcy
1 Leakage in swing motor
Malfunction of swing 2 motor (parking brake)
(1) The swing speed or acceleration is low in both directions.
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Left work equipment control lever
Leakage from swing motor
Swing relief (in either direction)
Max. 10 l/min
The parking brake of the swing motor may malfunction. Check it directly. a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
Wrong adjustment or 3 malfunction of swing motor (safety valve)
Left work equipment control lever
Swing relief pressure
Swing relief (in either direction)
28.4 –0.5 MPa
+2.5
+25
{290 –5 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction. check the safety valve directly. 4
Swing motor (motor unit) defective internally
The motor unit of the swing motor may have a defect in it. Check it directly.
5
Swing machinery defective internally
Swing machinery may have a defect in it. Check it directly. (The swing machinery can be checked by abnormal sound, abnormal heating, metal dust in the drained oil, etc.)
Failure Phenomenon
• Swing speed or acceleration is low
Related Information
• Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out troubleshooting related to it.) • When carrying out the following troubleshooting, set the working mode in the A-mode and turn the swing lock switch OFF. Cause
Presumed cause and standard value in normalcy
1
2
Malfunction of left PPC valve (swing circuit)
Malfunction of swing control valve (spool)
(2) The swing speed or acceleration is low in only 1 direction.
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Left work equipment control lever
PPC valve output pressure
Swing RIGHT/LEFT stroke end
Min. 2.74 MPa {Min. 28 kg/cm2}
The spool of the swing control valve may malfunction. Check it directly.
Malfunction of swing 3 control valve (suction valve)
The suction valve of the swing control valve may malfunction. Check it directly. (The suction valves of the right and left swing control valves can be checked by exchanging them with each other and seeing the change of the phenomenon.)
4
Malfunction of swing motor (suction valve)
The suction valve of the swing motor may malfunction. Check it directly. (The suction valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
5
Malfunction of swing motor (check valve)
The check valve of the swing motor may malfunction. Check it directly. (The check valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
PC750, 800-7
20-629 (1)
TROUBLESHOOTING
H-24
H-24 Swing speed or acceleration is low during compound operation of swing and work equipment Failure Phenomenon
• Swing speed or acceleration is low during compound operation of swing and work equipment
Related Information
• When carrying out the following troubleshooting, set the working mode in the A-mode and turn the swing lock switch OFF. Cause
(1) The swing speed or acceleration is low during compound operation of swing and work equipment with the swing priority mode OFF.
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
Presumed cause and standard value in normalcy
Malfunction of swing 1 priority solenoid valve
2
Solenoid valve outlet pressure
Swing priority switch OFF + Boom RAISE operation
Min. 2.35 MPa {Min. 24 kg/cm2}
Swing priority switch ON + Boom RAISE operation
0 Pa {0 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Right work equipment control lever
Swing PPC shuttle valve outlet pressure
Swing RIGHT/LEFT stroke end
Min. 2.74 MPa {Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. 3
Malfunction of swing priority selector valve
Right work equipment control lever
Swing priority selector valve outlet pressure (Port A2)
Neutral
0 Pa {0 kg/cm2}
Swing RIGHT/LEFT stroke end
Same as main pump pressure
Malfunction of arm 4 control valve (throttle valve)
The throttle valve of the arm control valve (Lo) may malfunction. Check it directly.
Malfunction of bucket 5 control valve (throttle valve)
The throttle valve of the bucket control valve (Hi) may malfunction. Check it directly.
20-630 (1)
Malfunction of swing PPC shuttle valve
Swing priority switch and right work equipment control lever
PC750, 800-7
TROUBLESHOOTING
H-24
Failure Phenomenon
• Swing speed or acceleration is low during compound operation of swing and work equipment
Related Information
• Before carry out the following troubleshooting, check that the swing speed is normal when the swing priority switch is turned OFF. • When carrying out the following troubleshooting, set the working mode in the A-mode and turn the swing lock switch OFF. Cause
(2) The swing speed or acceleration is low during compound operation of swing and work equipment with the swing priority mode ON.
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Malfunction of swing 1 priority solenoid valve
Swing priority switch and right work equipment control lever
Solenoid valve outlet pressure
Swing priority switch OFF + Boom RAISE operation
Min. 2.35 MPa {Min. 24 kg/cm2}
Swing priority switch ON + Boom RAISE operation
0 Pa {0 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. 2
Malfunction of swing priority selector valve
Malfunction of swing 3 control valve (throttle valve)
PC750, 800-7
Right work equipment control lever
Swing priority selector valve outlet pressure (Port A1)
Neutral
0 Pa {0 kg/cm2}
Boom RAISE stroke end
0 Pa {0 kg/cm2}
The throttle valve of the swing control valve may malfunction. Check it directly.
20-631 (1)
TROUBLESHOOTING
H-25
H-25 Upper structure overruns excessively when it stops swinging Failure Phenomenon
• Upper structure overruns excessively when it (1) The upper structure overruns excessively when it stops swinging stops swinging in both directions.
Related Information
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
Wrong adjustment or 1 malfunction of swing motor (safety valve)
Left work equipment control lever
Swing relief pressure
Swing relief (in either direction)
28.4 –0.5 MPa
+2.5
+25
{290 –5 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction. check the safety valve directly.
2 Leakage in swing motor
Failure Phenomenon
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Left work equipment control lever
Leakage from swing motor
Swing relief (in either direction)
Max. 10 l/min
• Upper structure overruns excessively when it (2) The upper structure overruns excessively when it stops swinging stops swinging in only 1 direction.
Related Information Cause
Presumed cause and standard value in normalcy
1
a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting. Left work equipment control lever
PPC valve output pressure
Swing RIGHT/LEFT stroke end
Min. 2.74 MPa {Min. 28 kg/cm2}
2
Malfunction of swing control valve (spool)
3
The suction valve of the swing control valve may malfunction. Check it directly. Malfunction of swing con(The suction valves of the right and left swing control valves can be checked by trol valve (suction valve) exchanging them with each other and seeing the change of the phenomenon.)
4
Malfunction of swing motor (suction valve)
The suction valve of the swing motor may malfunction. Check it directly. (The suction valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
5
Malfunction of swing motor (check valve)
The check valve of the swing motor may malfunction. Check it directly. (The check valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
20-632 (1)
Malfunction of left PPC valve (swing circuit)
Standard value in normalcy and references for troubleshooting
The spool of the swing control valve may malfunction. Check it directly.
PC750, 800-7
TROUBLESHOOTING
H-26
H-26 Large shock is made when upper structure stops swinging Failure Phenomenon
• Large shock is made when upper structure stops swinging
Related Information
• When carrying out the following troubleshooting, set the working mode in the A-mode and turn the swing lock switch OFF. Cause
(1) Large shock is made when the upper structure stops swinging in both directions.
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
Presumed cause and standard value in normalcy
Malfunction of swing 1 holding brake solenoid valve
2
Malfunction of swing motor (parking brake)
Left work equipment control lever
Solenoid valve outlet pressure
Neutral (After 5 seconds or more)
0 MPa {0 kg/cm2}
Operated to swing (in either direction)
Min. 2.74 MPa {Min. 28 kg/cm2}
The parking brake of the swing motor may malfunction. Check it directly. a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
Wrong adjustment or 3 malfunction of swing motor (safety valve)
Left work equipment control lever
Swing relief pressure +2.5
Swing relief (in either direction)
28.4 –0.5 MPa +25
{290 –5 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction. Check the safety valve directly. 4
Swing motor (motor unit) defective internally
The motor unit of the swing motor may have a defect in it. Check it directly.
5
Swing machinery defective internally
Swing machinery may have a defect in it. Check it directly. (The swing machinery can be checked by abnormal sound, abnormal heating, metal dust in the drained oil, etc.)
Failure Phenomenon
• Large shock is made when the upper structure stops swinging.
Related Information
• When carrying out the following troubleshooting, set the working mode in the A-mode and turn the swing lock switch OFF.
Presumed cause and standard value in normalcy
Cause
(2) Large shock is made when the upper structure stops swinging in only 1 direction.
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
1
Malfunction of left PPC valve (swing circuit)
Left work equipment control lever
PPC valve output pressure
Neutral
0 MPa {0 kg/cm2}
Swing RIGHT/LEFT stroke end
Min. 2.74 MPa {Min. 28 kg/cm2}
2
Malfunction of swing control valve (spool)
The spool of the swing control valve may malfunction. Check it directly.
3
Malfunction of swing motor (suction valve)
The suction valve of the swing motor may malfunction. Check it directly. (The suction valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
PC750, 800-7
20-633 (1)
TROUBLESHOOTING
H-27
H-27 Large abnormal sound is made when upper structure stops swinging Failure Phenomenon
• Large abnormal sound is made when upper structure stops swinging
(1) Large abnormal sound is made when the upper structure stops swinging in both directions.
Related Information
Presumed cause and standard value in normalcy
Cause Malfunction of back 1 pressure compensation valve
Standard value in normalcy and references for troubleshooting The back pressure compensation valve may malfunction. Check it directly. a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
Wrong adjustment or 2 malfunction of swing motor (safety valve)
Left work equipment control lever
Swing relief pressure +2.5
Swing relief (in either direction)
28.4 –0.5 MPa +25
{290 –5 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction. Check the safety valve directly. 3
Swing machinery defective internally
Failure Phenomenon
Swing machinery may have a defect in it. Check it directly. (The swing machinery can be checked by abnormal sound, abnormal heating, metal dust in the drained oil, etc.)
• Large abnormal sound is made when upper structure stops swinging
(2) Large abnormal sound is made when the upper structure stops swinging in only 1 direction.
Presumed cause and standard value in normalcy
Related Information Cause Malfunction of swing 1 control valve (suction valve)
2
20-634 (1)
Malfunction of swing motor (suction valve)
Standard value in normalcy and references for troubleshooting The suction valve of the swing control valve may malfunction. Check it directly. (The suction valves of the right and left swing control valves can be checked by exchanging them with each other and seeing the change of the phenomenon.) The suction valve of the swing motor may malfunction. Check it directly. (The suction valves of the right and left swing motors can be checked by exchanging them with each other and seeing the change of the phenomenon.)
PC750, 800-7
TROUBLESHOOTING
H-28
H-28 Hydraulic drift of swing is large Failure Phenomenon
• Hydraulic drift of swing is large
(1) While the swing holding brake is applied.
Presumed cause and standard value in normalcy
Related Information Cause
Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and run it at high idling during troubleshooting.
Malfunction of swing 1 holding brake solenoid valve
2
Malfunction of swing motor (parking brake)
Failure Phenomenon
Left work equipment control lever
Solenoid valve outlet pressure
Neutral (After 5 seconds or more)
0 MPa {0 kg/cm2}
Operated to swing (in either direction)
Min. 2.74 MPa {Min. 28 kg/cm2}
The parking brake of the swing motor may malfunction. Check it directly.
• Hydraulic drift of swing is large
(2) While the swing holding brake is released.
Related Information
Presumed cause and standard value in normalcy
Cause 1
Malfunction of swing control valve (spool)
Malfunction of swing 2 control valve (suction valve)
Standard value in normalcy and references for troubleshooting The spool of the swing control valve may malfunction. Check it directly. The suction valve of the swing control valve may malfunction. Check it directly.
3
Malfunction of swing motor (safety valve)
The safety valve of the swing motor may malfunction. Check it directly.
4
Malfunction of swing motor (suction valve)
The suction valve of the swing motor may malfunction. Check it directly.
5
Malfunction of swing motor (check valve)
The check valve of the swing motor may malfunction. Check it directly.
PC750, 800-7
20-635 (1)
TROUBLESHOOTING OF ENGINE (S MODE) POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-702 METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-703 S-1 Starting performance is poor (starting always takes time).................................................................... 20-706 S-2 Engine does not start ........................................................................................................................... 20-707 S-3 Engine does not pick up smoothly (follow-up is poor) .......................................................................... 20-710 S-4 Engine stops during operations ............................................................................................................ 20- 711 S-5 Engine does not rotate smoothly (hunting)........................................................................................... 20-712 S-6 Engine lacks output (or lacks power) ................................................................................................... 20-713 S-7 Exhaust smoke is black (incomplete combustion)................................................................................ 20-714 S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 20-715 S-9 Oil becomes contaminated quickly ....................................................................................................... 20-716 S-10 Fuel consumption is excessive........................................................................................................... 20-717 S-11 Oil is in cooling water (or water spurts back, or water level goes down) ............................................ 20-718 S-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................................. 20-719 S-13 Oil level rises (water, fuel in oil) .......................................................................................................... 20-720 S-14 Water temperature becomes too high (overheating) .......................................................................... 20-721 S-15 Abnormal noise is made..................................................................................................................... 20-722 S-16 Vibration is excessive ......................................................................................................................... 20-723
PC750, 800-7
20-701 (1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
k Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the parking brake is securely applied.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. k If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious burns. Always wait for the water temperature to go down before removing the radiator cap. k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing a plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?
3. Checks before troubleshooting 1) Is there any sign of abnormality in the machine or engine? 2) Always carry out the Checks before starting. 3) Carry out other checks if necessary. 4) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 5) Check for any error display on the controller. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to re-enact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Us e th e r e s u l ts o f t he i nv e s ti g a ti o n a n d inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting matrix or flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
20-702 (1)
PC750, 800-7
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation.
[Questions] Sections + in the chart on the right corresponds to the items where answers can be obtained from the user. The items in are items that can be obtained from the user, depending on the user's level.
[Check items] The serviceman carries out simple inspection to narrow down the causes. The items under in the chart on the right correspond to this. The serviceman narrows down the causes from information that he has obtained from the user and the results of that he has obtained from his own inspection.
[Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items]. The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with , and of these, causes that have a high probability are marked with . Check each of the [Questions] and [Check items] in turn, and marked the or in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting. Use the in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference.
PC750, 800-7
20-703 (1)
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
Exhaust smoke is black S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black • Insufficient intake of air • There is excessive fuel. • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating a See troubleshooting for [Overheat]. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)
20-704 (1)
PC750, 800-7
TROUBLESHOOTING
PC750, 800-7
METHOD OF USING TROUBLESHOOTING CHARTS
20-705 (1)
TROUBLESHOOTING
S-1
S-1 Starting performance is poor (starting always takes time) General causes why starting performance is poor • Defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel a With the common rail fuel injection system, the fuel injection timing is recognized electrically, so even when the starting operation is carried out, the engine may not start until the crankshaft has completed two rotations. However, this does not indicate any abnormality.
20-706 (1)
PC750, 800-7
TROUBLESHOOTING
S-2
S-2 Engine does not start a) Engine does not turn General causes why engine does not turn • Internal parts of engine seized a See "Engine stops during operations". • Defective electrical system • Failure on chassis side
PC750, 800-7
20-707 (1)
TROUBLESHOOTING
S-2
b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out • Fuel is not being supplied • Supply of fuel is extremely small • Improper selection of fuel (particularly in winter)
20-708 (1)
PC750, 800-7
TROUBLESHOOTING
S-2
c) Exhaust smoke comes out but engine does not start (Fuel is being injected) General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel
PC750, 800-7
20-709 (1)
TROUBLESHOOTING
S-3
S-3 Engine does not pick up smoothly (follow-up is poor) General causes why engine does not pick up smoothly • Insufficient intake of air • Insufficient supply of fuel • Abnormal fuel injection condition • Improper selection of fuel • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)
20-710 (1)
PC750, 800-7
TROUBLESHOOTING
S-4
S-4 Engine stops during operations General causes why engine stops • Internal part of engine seized • Insufficient supply of fuel • Engine overheating a See troubleshooting for [Overheat]. • Failure on chassis side
PC750, 800-7
20-711 (1)
TROUBLESHOOTING
S-5
S-5 Engine does not rotate smoothly (hunting) General causes why engine does not rotate smoothly • Air in fuel system • Speed sensor is not normal (abnormality not big enough to generate error display)
20-712 (1)
PC750, 800-7
TROUBLESHOOTING
S-6
S-6 Engine lacks output (or lacks power) General causes why engine lacks output • Insufficient intake of air • Insufficient supply of fuel • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating a See troubleshooting for [Overheat]. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)
PC750, 800-7
20-713 (1)
TROUBLESHOOTING
S-7
S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black • Insufficient intake of air • There is excessive fuel. • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating a See troubleshooting for [Overheat]. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)
20-714 (1)
PC750, 800-7
TROUBLESHOOTING
S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive • Abnormal combustion of oil • The engine has been run at low or high idling for a long time continuously (more than 20 minutes continuous operation is not allowed). • External leakage of oil • Wear of lubrication system
PC750, 800-7
20-715 (1)
TROUBLESHOOTING
S-9
S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly • Entry of exhaust gas into oil due to internal wear • Clogging of lubrication passage • Improper fuel used • Improper oil used • Operation under excessive load
20-716 (1)
PC750, 800-7
TROUBLESHOOTING
S-10
S-10 Fuel consumption is excessive General causes why fuel consumption is excessive • Leakage of fuel • Improper condition of fuel injection (injection pressure, injection timing) • Excessive injection of fuel
PC750, 800-7
20-717 (1)
TROUBLESHOOTING
S-11
S-11 Oil is in cooling water (or water spurts back, or water level goes down) General causes why oil is in cooling water • Internal leakage in lubrication system • Internal leakage in cooling system
20-718 (1)
PC750, 800-7
TROUBLESHOOTING
S-12
S-12 Oil pressure caution lamp lights up (drop in oil pressure) General causes why oil pressure drops • Leakage, clogging, wear of lubricating system • Defective oil pressure control • Improper oil used (improper viscosity) • Deterioration of oil due to overheating
PC750, 800-7
20-719 (1)
TROUBLESHOOTING
S-13
S-13 Oil level rises (water, fuel in oil) General causes why oil level rises • Water in oil (cloudy white) • Fuel in oil (diluted, smells of diesel fuel) a If there is oil in the cooling water, carry out troubleshooting for "Oil is in cooling water".
20-720 (1)
PC750, 800-7
TROUBLESHOOTING
S-14
S-14 Water temperature becomes too high (overheating) General causes why water temperature becomes too high • Lack of cooling air (deformation, damage of fan) • Drop in heat dissipation efficiency • Defective cooling circulation system • Rise of hydraulic oil temperature on chassis side
PC750, 800-7
20-721 (1)
TROUBLESHOOTING
S-15
S-15 Abnormal noise is made General causes why abnormal noise is made • Abnormality due to defective parts • Abnormal combustion • Air sucked in from intake system a Judge if the noise is an internal noise or an external noise. a If the engine is not thoroughly warmed up, the engine sound becomes slightly louder because it is operated in the low temperature mode, but this is not an abnormality. a When the engine is accelerated, it enters the acceleration mode and the engine noise is higher for 3 seconds, but this is not an abnormality.
20-722 (1)
PC750, 800-7
TROUBLESHOOTING
S-16
S-16 Vibration is excessive General causes why vibration is excessive • Defective parts (abnormal wear, breakage) • Improper alignment with machine • Abnormal combustion a If there is abnormal noise together with the vibration, carry out troubleshooting also for "Abnormal noise is made".
PC750, 800-7
20-723 (1)
30 DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL.....................30PRECAUTIONS WHEN CARRYING OUT OPERATION ............................................30SPECIAL TOOL LIST .................................... 30REMOVAL AND INSTALLATION OF AFTERCOOLER CORE...........................30REMOVAL AND INSTALLATION OF FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY ....................... 30REMOVAL AND INSTALLATION OF FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY ...................... 30REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY.................................... 30REMOVAL AND INSTALLATION OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY................................... 30REMOVAL AND INSTALLATION OF PTO ASSEMBLY .............................................. 30DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY .............................................. 30DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY....................... 30REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY...........30REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY .......... 30DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY .......... 30REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY................... 30REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY...................... 30DISASSEMBLY AND ASSEMBLY OF ONE LINK IN FIELD .........................................30REMOVAL AND INSTALLATION OF IDLER ASSEMBLY .............................................. 30DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY ..................................30DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY..30REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY ................. 30DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY................ 30PC750, 800-7
3 5 7 14 15 18 19 20 24 26 29 40 41 42 49 50 52 56 57 60 61 63
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY ............. 30- 65 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY ............. 30- 66 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY ................. 30- 69 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY ................. 30- 70 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY.............. 30- 73 REMOVAL AND INSTALLATION OF MAIN PUMP (NO. 1 PUMP) ASSEMBLY .......... 30- 75 REMOVAL AND INSTALLATION OF MAIN PUMP (NO. 2 PUMP) .............................. 30- 77 REMOVAL AND INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL ............. 30- 79 REMOVAL AND INSTALLATION OF CONTROL AND PTO LUBRICATION PUMP ASSEMBLY .................................. 30- 80 DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY .................... 30- 81 REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY ............... 30- 82 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (WORK EQUIPMENT) ............................. 30- 85 REMOVAL AND INSTALLATION OF SOLENOID VALVE ASSEMBLY .............. 30- 88 REMOVAL AND INSTALLATION OF BOOM DAMPING VALVE ASSEMBLY................ 30- 90 REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY .................. 30- 91 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ........................ 30- 93 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY .... 30- 94 REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY................. 30- 96 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.............................................. 30- 97 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY........... 30- 99 REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (BACK HOE)..... 30-101
30-1 (2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL)............................... 30-103 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (BACK HOE) .... 30-105 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (LOADING SHOVEL)............................... 30-107 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (BACK HOE) .... 30-109 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (LOADING SHOVEL)............................... 30- 111 REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL)............................... 30-113 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY..... 30-114 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (BACK HOE)........................ 30-120 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (LOADING SHOVEL) .......... 30-121 REMOVAL AND INSTALLATION OF ARM ASSEMBLY (BACK HOE)........................ 30-122 REMOVAL AND INSTALLATION OF ARM ASSEMBLY (LOADING SHOVEL) .......... 30-124 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (BACK HOE)........................ 30-126 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (LOADING SHOVEL) .......... 30-128 REMOVAL AND INSTALLATION OF WORK EQUIPMENT (BACK HOE) ..................... 30-130 REMOVAL AND INSTALLATION OF WORK EQUIPMENT (LOADING SHOVEL) ........ 30-132 REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY ............. 30-134 REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS) ..................................... 30-136 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY ............................. 30-146 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY............. 30-152
30-2 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
METHOD OF USING MANUAL REMOVAL AND INSTALLATION OF ASSEMBLIES SPECIAL TOOLS • Special tools that are deemed necessary for removal or installation of parts are listed. • List of the special tools contains the following kind of information. 1) Necessity t: Special tools which cannot be substituted, should always be used. q: Special tools which are very useful if available, can be substituted with commercially available tools. 2) Distinction of new and existing special tools N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blank: Tools already available for other models, used without any modification. 3) Circle mark (Q) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools. a Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
INSTALLATION OF PARTS • Except where otherwise instructed, install parts is the reverse order of removal. • Instructions and precautions for installing parts are shown with mark in the INSTALLATION Section, identifying which step the instructions are intended for. • Marks shown in the INSTALLATION Section stand for the following. k
This mark indicates safety-related precautions which must be followed when doing the work. a This mark gives guidance or precautions when doing the procedure. 2 This mark stands for a specific coating agent to be used. 3 This mark indicates the specified torque. 5 This mark indicates an amount of oil or water to be added. SKETCHES OF SPECIAL TOOLS • Various special tools are illustrated for the convenience of local manufacture.
REMOVAL OF PARTS • The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained. • Various symbols used in the REMOVAL Section are explained and listed below. k
a
This mark indicates safety-related precautions which must be followed when doing the work. This mark gives guidance or precautions when doing the procedure. This mark shows that there are instructions or precautions for installing parts.
6 This mark shows oil or water to be drained.
PC750, 800-7
30-3 (2)
DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES SPECIAL TOOLS • Special tools which are deemed necessary for disassembly and assembly are listed in this section. • List of the special tools contains the following kind of information. 1) Necessity t: Special tools which cannot be substituted, should always be used. q: Special tools which are very useful if available, can be substituted with commercially available tools. 2) Distinction of new and existing special tools N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blank: Tools already available for other models, used without any modification. 3) Circle mark (Q) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools.
ASSEMBLY • Section titled ASSEMBLY contain procedures, precautions and the know-how for the work, as well as the amount of oil or water to be added. • Various symbols used in the ASSEMBLY Section are explained and listed below. k
This mark indicates safety-related precautions which must be followed when doing the work. a This mark gives guidance or precautions when doing the procedure. 2 This mark stands for a specific coating agent to be used. 3 This mark indicates the specified torque. 5 This mark indicates an amount of oil or water to be added. SKETCHES OF SPECIAL TOOLS 1) Various special tools are illustrated for the convenience of local manufacture.
4) Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T--- xxx --- xxxx. DISASSEMBLY • The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water to be drained. • Various symbols used in the DISASSEMBLY Section are explained and listed below. k
a
This mark indicates safety-related precautions which must be followed when doing the work. This mark gives guidance or precautions when doing the procedure. This mark shows that there are instructions or precautions for installing parts.
6 This mark shows oil or water to be drained.
30-4 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work • If the coolant contains antifreeze, dispose of it correctly. • After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. • When draining oil, prepare a container of adequate size to catch the oil. • Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. • To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. • Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. • Check the number and thickness of the shims, and keep in a safe place. • When raising components, be sure to use lifting equipment of ample strength. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. a Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number
Plug (nut end)
Nut (elbow end)
02
07376-70210
02789-00210
03
07376-70315
02789-00315
04
07376-70422
02789-00422
05
07376-70522
02789-00522
06
07376-70628
02789-00628
2) Split flange type hoses and tubes Nominal number
Flange (hose end)
Sleeve head (tube end)
Split flange
04
07379-00400
07378-10400
07371-30400
05
07379-00500
07378-10500
07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
06
Dimensions D
d
L
07049-00608
6
5
8
08
07049-00811
8
6.5
11
10
07049-01012
10
8.5
12
12
07049-01215
12
10
15
14
07049-01418
14 11.5 18
16
07049-01620
16 13.5 20
18
07049-01822
18
15
22
20
07049-02025
20
17
25
22
07049-02228
22 18.5 28
24
07049-02430
24
27
07049-02734
27 22.5 34
PC750, 800-7
20
Taper 1/8
ød
Part Number
øD
Nominal number
L
DEW00401
30
30-5 (2)
DISASSEMBLY AND ASSEMBLY
2. • • • • • • • • • • • • •
PRECAUTIONS WHEN CARRYING OUT OPERATION
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idling. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. a When using the machine for the first time after repair or long storage, follow the same procedure. 3. Precautions when completing the operation • If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. • If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. • If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see TESTING AND ADJUSTING, Bleeding air. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-6 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
SPECIAL TOOL LIST a Tools with part number 79 Ttured).
-
cannot be supplied (they are items to be locally manufac-
a Necessity:
t............Cannot be substituted, must always be installed (used) q............Extremely useful if available or can be substituted with commercially available part a New/Remodel: N ...........Tools with new part numbers, newly developed for this model R: ...........Tools with upgraded part numbers, remodeled from items already available for other models Blank: ... Tools already available for other models, can be used without any modification
1
• 790-101-5421 • Grip
t
1
Swing machinery assembly
• 01010-81240 • Bolt
t
1
790-201-2780
Spacer
t
1
790-201-2880
Spacer
t
1
3 796T-626-1130 Push tool
t
1
1 796-627-1050
Installer
t
1
2 796-627-1030
Push tool
t
1
Push-puller
t
1
• 790-101-2310 • Block
t
1
• 790-101-2350 • Leg
t
2
• 790-101-2360 • Plate
t
2
• 02215-11622 • Nut
t
2
791-181-1010
t
2
t
1
F
Disassembly, assembly
t
1
Push tool kit
2
790-101-2300
3 Final drive assembly
796T-627-1340 Push tool
J
N Q
N Q
t
1
790-101-1102
Pump
t
1
Wrench assembly
t
1
N
Spacer
t
1
N
5 01017-52450
Bolt
t
1
01580-12419
Nut
t
1
790-201-2830
Spacer
t
1
790-101-5151
Plate
t
1
6
Press fitting of main bearing Press fitting of main bearing Press fitting of sub bearing Press fitting of bearing outer race
R
Puller (294 kN {30 ton})
796-627-1070
Press fitting of oil seal
Installation of floating seal
790-101-2102
4 790-627-1200
PC750, 800-7
Adapter
Nature of work, remarks
Disassembly, assembly
• 790-101-5541 • Plate
790-101-5401
Part Name
Sketch
1
Part No.
New/remodel
Q'ty
t
Symbol
Component
Necessity
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See SKETCHES OF SPECIAL TOOLS).
Press fitting of bearing inner race
Long stroke
Removal, installation of round nut Removal of No. 1 carrier pin holder Removal of No. 1 carrier pin
30-7 (2)
t
1
Final drive assembly
• 01010-51240 • Bolt
t
1
790-101-5001
t
1
t
1
t
1
• 790-101-5021 • Grip
t
1
796-660-1560
Guide bolt
t
2
1 790-201-2680
Plate
t
1
2 796-675-1510
Installer
t
1
3 790-1101-5401 Push tool kit (C)
t
1
4 796T-630-1130 Push tool
t
1
5 796T-630-1140 Adapter
t
1
6 791-670-1010
Installer
t
1
790-401-1700
Lifting tool
t
1
790-401-1761
Adapter
t
1
790-401-1540
Shackle
t
2
790-401-1770
T-bolt
t
2
8 791-580-1520
Installer
t
1
9 790-201-2670
Plate
t
1
Oil pump
t
1
J
Push tool kit (A)
8 • 790-101-5151 • Plate • 790-101-5061 • Plate
Travel motor assembly
K
Disassembly, assembly
• 790-101-5421 • Grip
N
Idler assembly
Carrier roller assembly
L 7
Track roller assembly
791-601-1000 10
30-8 (2)
t
or 791-646-8002
Oil lubricator
t
1
790-701-3000
Seal checker
t
1
N Q
Disassembly, Removal, assembly installation
1
Disassembly, assembly
t
7
Push tool kit (C)
Nature of work, remarks
Press fitting of bearing outer race Press fitting of needle bearing No. 2 carrier No. 3 carrier
Removal, installation of travel motor assembly Press fitting of idler bushing Installation of idler floating seal Press fitting of carrier roller bearing Installation of floating seal Press fitting of carrier roller bearing inner race Installation of floating seal
Disassembly, assembly
• 790-101-5441 • Plate
790-101-5401
Part Name
Sketch
1
Part No.
New/remodel
Q'ty
t
Symbol
Component
SPECIAL TOOL LIST
Necessity
DISASSEMBLY AND ASSEMBLY
Removal, installation of track roller assembly Installation of floating seal Press fitting of track roller bushing Filling with oil, checking sealing
PC750, 800-7
t
1
790-101-1102
Pump
t
1
Wrench
t
1
791-685-8501
Compressor
t
1
791-635-3160
Extension
t
1
796-630-1110
Plate
t
1
01010-51640
Bolt
t
2
Spacer
t
1
790-101-1600
Cylinder (686 kN {70 ton})
t
1
790-010-1102
Pump
t
1
796-630-1110
Plate
t
1
791-680-9580
Adapter
t
1
791-680-9590
Guide
t
1
01010-52760
Bolt
t
2
01010-51440
Bolt
t
2
790-101-1102
Pump
t
1
790-101-4300
Cylinder
t
1
791-685-9510
Frame
t
1
791-685-9520
Frame
t
1
791-685-9530
Rod
t
1
791-685-9550
Nut
t
1
791-685-9560
Bolt
t
4
791-680-9570
Adapter
t
1
01010-51030
Bolt
t
1
04530-12030
Eyebolt
t
1
790-101-1102
Pump
t
1
790-101-4300
Cylinder
t
1
791-685-9540
Rod
t
1
791-685-9550
Nut
t
3
2 790-331-1100 M
Recoil spring assembly
3 796-630-1120
1
2
Track link remover N
3
4
PC750, 800-7
Removal, installation
790-101-4200
Puller (294 kN {30 ton})
Disassembly, assembly
1
Disassembly, assembly
Cylinder (1,471 kN t {150 ton})
Removal, installation of master pin
Tightening shoe bolt angle
Disassembly, assembly of recoil spring
1,471 kN {150 ton}
Assembly
790-101-4300
Nature of work, remarks
Disassembly, assembly
1
Sketch
Remover, installer t
Part Name
New/remodel
Q'ty
791-680-9501
Part No.
1
Track shoe assembly
SPECIAL TOOL LIST
Necessity
Component
Symbol
DISASSEMBLY AND ASSEMBLY
1,471 kN {150 ton}
30-9 (2)
Q'ty
Frame
t
1
791-685-9520
Frame
t
1
791-685-9530
Rod
t
1
791-685-9550
Nut
t
1
791-685-9560
Bolt
t
4
791-126-0150
Adapter
t
1
791-680-5520
Guide
t
1
791-126-0140
Pusher
t
1
791-680-9570
Adapter
t
1
01010-51030
Bolt
t
1
04530-12030
Eyebolt
t
1
791-685-9620
Extension
t
1
790-101-1102
Pump
t
1
790-101-4300
Cylinder
t
1
790-101-1102
Pump
t
1
790-101-4200
Pulley
t
1
294 kN {30 ton}
791-680-5542
Adapter
t
1
Press fitting of regular pin
791-632-1110
Adapter
t
1
8 791-680-5580
Guide
t
1
791-685-9510
Frame
t
1
791-685-9520
Frame
t
1
791-685-9530
Rod
t
1
791-685-9540
Rod
t
1
791-685-9550
Nut
t
3
791-685-9560
Bolt
t
4
Adapter
t
1
01010-51030
Bolt
t
1
791-685-9620
Extension
t
1
791-680-5542
Adapter
t
1
791-680-5560
Guide
t
1
790-101-1102
Pump
t
1
790-101-4300
Cylinder
t
1
791-685-9510
Frame
t
1
791-685-9520
Frame
t
1
791-685-9530
Rod
t
1
791-685-9540
Rod
t
1
791-685-9550
Nut
t
3
791-685-9560
Bolt
t
4
791-126-0150
Adapter
t
1
01010-51030
Bolt
t
1
7
N
9 791-126-0150
Track link installer
10
30-10 (2)
Disassembly, assembly 1,471 kN {150 ton}
Disassembly
6
Nature of work, remarks
Press fitting of bushing
Assembly
Track link remover
Part Name
Disassembly, assembly
5
Part No.
Sketch
Necessity
791-685-9510
Symbol
Component
SPECIAL TOOL LIST
New/remodel
DISASSEMBLY AND ASSEMBLY
1,471 kN {150 ton}
PC750, 800-7
Q'ty
Extension
t
1
791-680-5560
Guide
t
1
791-632-1110
Adapter
t
1
791-680-9630
Adapter
t
1
790-101-1102
Pump
t
1
790-101-4300
Cylinder
t
1
11 791-680-1520
Guide
t
1
791-685-9510
Frame
t
1
791-685-9520
Frame
t
1
791-685-9530
Rod
t
1
791-685-9540
Rod
t
1
791-685-9550
Nut
t
3
791-685-9560
Bolt
t
4
Adapter
t
1
791-680-5560
Guide
t
1
791-680-9570
Adapter
t
1
01010-51030
Bolt
t
1
791-680-1520
Guide
t
1
790-101-1102
Pump
t
1
790-101-4300
Cylinder
t
1
790-101-1102
Pump
t
1
790-101-4200
Pulley
t
1
294 kN {30 ton}
791-680-9501
Remover, installer t
1
Kit
790-101-1102
Pump
t
1
790-101-4200
Pulley
t
1
294 kN {30 ton}
790-101-4300
Cylinder
t
1
1,471 kN {150 ton}
1 796-770-1301
Oil stopper
t
1
2 209-60-71130
Rod assembly
t
1
Push tool kit
t
1
4 • 790-101-5151 • Plate
t
1
5 • 790-101-5021 • Grip
t
1
6 01010-50816
t
1
12 791-126-0150
13
Track link remover, installer
Hydraulic pump assembly
PC750, 800-7
14
S 3 790-101-5001
• Bolt
1,471 kN {150 ton}
Disassembly, assembly
N
Nature of work, remarks
1,471 kN {150 ton}
Removal, installation
Track link installer
Part Name
Removal, installation of hydraulic pump
Disassembly, assembly
10
Part No.
Sketch
Necessity
791-685-9620
Symbol
Component
SPECIAL TOOL LIST
New/remodel
DISASSEMBLY AND ASSEMBLY
Press fitting of oil seal (hydraulic pump shaft)
30-11 (2)
t
1
• 790-101-2520 • Screw
t
1
• 791-112-1180 • Nut
t
1
T
• 790-101-2540 • Washer
t
1
• 790-101-2630 • Leg
t
2
• 790-101-2570 • Plate
t
2
• 790-101-2560 • Nut
t
2
• 790-101-2660 • Adapter
t
2
Nature of work, remarks
Disassembly, assembly
• 790-101-2510 • Block
Push-puller
Sketch
1
Part Name
New/remodel
Q'ty
t
Part No.
790-101-2501
Center swivel joint assembly
SPECIAL TOOL LIST
Necessity
Component
Symbol
DISASSEMBLY AND ASSEMBLY
Disassembly of center swivel joint
1 790-502-1003
Cylinder repair stand
t
2
2 790-720-1000
Expander
t
1
796-720-1690
Ring
t
1
796-720-1720
Ring
t
1
07281-02169
Clamp
t
1
796-720-1690
Ring
t
1
07281-01919
Clamp
t
1
07281-02429
Clamp
t
1
Bucket cylinder (for SE)
790-201-1702
Push tool kit
t
1
Press fitting of coil bushing
• 790-201-1881 • Push tool
t
1
Boom, arm cylinder
• 790-201-1871 • Push tool
t
1
Hydraulic cylinder 4 • 791-863-1110 • Push tool U assembly • 790-101-5421 • Grip
Arm cylinder (for SE), bucket cylinder
t
1
t
1
• 01010-51240 • Bolt
t
1
• 790-101-5021 • Grip
t
1
• 01010-50816 • Bolt
t
1
790-201-1500
t
1
Press fitting of dust seal
• 790-201-1690 • Plate
t
1
Boom, arm cylinder
• 790-201-1680 • Plate
t
1
• 792-715-1400 • Push tool
t
1
• 790-101-5421 • Grip
t
1
• 01010-51240 • Bolt
t
1
• 790-101-5021 • Grip
t
1
• 01010-51240 • Bolt
t
1
6
30-12 (2)
Disassembly
Installation of piston ring Boom, arm cylinder Bucket cylinder (for SE) Boom, arm cylinder
Assembly
Bucket cylinder
Bucket cylinder (for SE) All cylinders
Assembly
5
Push tool kit
N Q
Disassembly, assembly
3
Disassembly, assembly of hydraulic cylinder
Bucket cylinder Bucket cylinder (for SE)
Press fitting of dust seal All cylinders
PC750, 800-7
Q'ty
Remover
t
1
Removal of boom foot pin, boom cylinder bottom pin
790-101-4200
Puller (294 kN {30 ton})
t
1
Short stroke
790-101-1102
Pump
t
1
791-650-1610
Bracket
t
1
790-445-4130
Screw
t
1
791-112-1180
Nut
t
1
Washer
t
1
790-101-2102
Puller (294 kN {30 ton})
t
1
790-101-1102
Pump
t
1
790-445-4120
Sleeve
t
1
791-520-4140
Screw
t
1
796-775-1110
Adapter
t
1
Nut
t
1
Washer
t
1
790-101-2102
Puller (294 kN {30 ton})
t
1
790-101-1102
Sleeve
t
1
799-703-1200
Service tool kit
t
1
799-703-1100
Vacuum pump (100 V)
t
1
799-703-1110
Vacuum pump (220 V)
t
1
799-703-1120
Vacuum pump (240 V)
t
1
799-703-1400
Gas leak detector
t
1
1 793-498-1210
Lifter (Suction cup)
t
2
2 20Y-54-13180
Adapter
t
2
V
3 791-112-1180 01643-32780
Air conditioner system
Operator’s cab glass
PC750, 800-7
X
Y
Removal, installation
Work equipment assembly
Nature of work, remarks
Removal of arm cylinder rod head and bottom pin
Long stroke
Removal of boom top pin and boom cylinder head pin Boom top pin only
Removal, installation
2 01643-32780
Part Name
Charging with freon gas (R134a)
Installation
1
Part No.
Sketch
Necessity
790-445-4100
Symbol
Component
SPECIAL TOOL LIST
New/remodel
DISASSEMBLY AND ASSEMBLY
Installation of operator’s cab glass
30-13 (2)
DISASSEMBLY AND ASSEMBLY
AFTERCOOLER CORE
REMOVAL AND INSTALLATION OF AFTERCOOLER CORE REMOVAL 1. Lift off radiator grille (1).
INSTALLATION •
Carry out installation in the reverse order to removal.
2. Lift off radiator top cover (2).
3. Loosen clamps (3) of rubber hose.
4. Sling aftercooler core (4), remove mounting bolts, and pull out from rubber hose while lifting off.
30-14 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER
REMOVAL AND INSTALLATION OF FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY
X
Part No.
3. Remove the radiator grille (2) and the cover (3).
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
799-703-1200 Service tool kit
t 1
799-703-1100
Vacuum pump (100V)
t 1
799-703-1110
Vacuum pump (220V)
t 1
799-703-1120
Vacuum pump (240V)
t 1
799-703-1400
Gas leak t 1 detector (100V)
4. Loosen 2 bolts of the radiator grille (2) and open the grille. a Remove the air conditioner condenser, the fuel cooler and the after cooler referring to the paragraph of Removal of Air Conditioner Condenser, Fuel Cooler and After Cooler.
REMOVAL k
Disconnect the (–) terminal of the battery in advance. k Open the engine hood, and press the valve of the compressor hose for the air conditioner slowly to release refrigerant (R134a) gradually. k Lower the work equipment completely to the ground and stop the engine. Loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure.
5. Remove the brackets (5) of the air conditioner condenser and the fuel cooler.
1. Drain coolant, hydraulic oil and fuel. Recall the air conditioner gas. 2. Lift the engine hood (1) on the front side and remove it. 6. Disconnect the radiator cooler tube (6) and the radiator cooler hose (7). 7. Remove the fuel cooler hose clamp (8).
PC750, 800-7
30-15 (2)
DISASSEMBLY AND ASSEMBLY
FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER
8. Remove 3 pieces of the hose clamp (9) of the air conditioner condenser.
14. Lift the fan guard, radiator and hydraulic oil cooler assembly temporarily and remove the mounting bolts (17).
9. Remove 2 pieces of the plate (10). 15. Remove the fan guard, radiator and hydraulic oil cooler assembly (18). 4
Fan guard, radiator and hydraulic oil cooler assembly: 950 kg
10. Disconnect the air intake hose (11) and the air intake tube (12). 11. Disconnect the hoses (13), (14) and (15). 12. Reduce the tension of the tension pulley by using a lever block, for example, and remove the fan belt.
16. Lower the fan pulley and set the block between the fan guard, radiator and hydraulic oil cooler assembly and the ground. 13. Loosen the bolt of the frame (16) and remove it. 17. Lift the hydraulic oil cooler assembly (19) temporarily, remove 8 pieces of the mounting bolt (20) and then remove the hydraulic oil cooler assembly. 4
Hydraulic oil cooler assembly: 200 kg
18. Lift the radiator (21) temporarily and remove 8 pieces of the mounting bolt (22).
30-16 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER
INSTALLATION
19. Remove the isolator (23) and then remove the radiator assembly. 4
•
To install this assembly, reverse the removing procedures.
•
Water Filling a Fill water up to the specified level through the water filler port, start the engine to circulate coolant and check the water level again.
•
Filling (Hydraulic Tank) with Oil a Fill oil up to the specified level through the oil filler port, start the engine to circulate oil through the pipe and check the oil level again.
•
Filling of Air Conditioner Gas a Use the tool X and fill the air conditioner circuit with refrigerant (R134a).
•
Alignment of Engine Pulley and Fan Pulley a Assemble them so that the engine pulley aligns with the fan pulley within 3 mm.
•
Filling (Fuel Tank) with Diesel Fuel a Fill the fuel tank with diesel fuel through the oil filler port and bleed air by the specified method (See the Operation and Maintenance Manual).
Radiator assembly: 260 kg
PC750, 800-7
30-17 (2)
DISASSEMBLY AND ASSEMBLY
FUEL COOLER AND AIR CONDITIONER CONDENSER
REMOVAL AND INSTALLATION OF FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY
X
Part No.
3. Remove the fuel cooler guard (3).
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
799-703-1200 Service tool kit
t 1
799-703-1100
Vacuum pump (100V)
t 1
799-703-1110
Vacuum pump (220V)
t 1
799-703-1120
Vacuum pump (240V)
t 1
799-703-1400
Gas leak t 1 detector (100V)
REMOVAL k
Lower the work equipment completely to the ground and stop the engine. Loosen the cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. k Connect the tool X to the valve of the air compressor hose and recall new Freon gas (R134a).
4. Disconnect the fuel cooler hose quick coupler (4) and (5). 5. Loosen 4 pieces of the fuel cooler mounting bolt (6) and remove the fuel cooler (7).
6. Disconnect the air conditioner condenser hoses (8) and (9). 7. Loosen 4 pieces of the air conditioner condenser mounting bolt (10) and remove the air conditioner condenser (11).
1. Shut the valve (1) of the fuel tank.
INSTALLATION 2. Open the radiator grille (2).
30-18 (2)
•
To install this assembly, reverse the removing procedures. a Fill new Freon gas (R134a).
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
FUEL TANK
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY REMOVAL k
Disconnect the (–) terminal of the battery in advance.
5. Disconnect the fuel supply hose (5) and the drain hose (6).
1. Open the drain valve and drain fuel. 6
Fuel tank: 880 l (when the tank is fully filled)
2. Remove the handrail (1).
6. Remove the control valve cover bracket (7).
3. Remove the fuel gauge cover (2) and the fuel gauge wiring cover (3), and disconnect the wiring connector.
7. Loosen the mounting bolt, lift the fuel tank assembly and remove it. 4
Fuel tank assembly: 498 kg
4. Disconnect the fuel return hoses (4) and (5) and remove the hose clamps.
INSTALLATION •
PC750, 800-7
To install this assembly, reverse the removing procedures. 3 Fuel tank mounting bolt: 549 ± 58 Nm {56 ± 6kgm}
30-19 (2)
DISASSEMBLY AND ASSEMBLY
ENGINE, PTO AND HYDRAULIC PUMP
REMOVAL AND INSTALLATION OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY
Part No.
Part Name
S 1 796-770-1301 Oil stopper
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
t 1
REMOVAL k
Lower the work equipment completely to the ground and stop the engine. Loosen the cap of the hydraulic tank slowly to release internal pressure of the hydraulic tank. k Drain engine oil. k Disconnect the (–) terminal of the battery. a Put counter marks on each hose and tube, and attach oil stopper plugs to the disconnected hoses and tubes.
4. Remove the radiator cover (4). 5. Remove the engine hood (5). 6. Remove the main pump cover (6).
1. Remove the strainer from the fuel tank and use the oil stopper tool S1 to stop oil flow. • When the tool S1 is not used, remove the drain plug and drain oil. 6
Hydraulic tank: 500 l
2. Drain coolant. 3. Remove the engine oil filter cover (1) and remove the oil filter assembly (2) together with the bracket (3) from the engine hood. Place them on the control valve side.
30-20 (2)
7. Remove the partition cover (7) between the engine and the main pump.
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
Engine Left Side 8. Remove the air compressor cover (8) and loosen the belt adjustment bolt to remove the belt.
ENGINE, PTO AND HYDRAULIC PUMP
14. Disconnect the air cleaner dust indicator hose (19) and remove the wiring connector (20).
9. Loosen 4 pieces of the compressor mounting bolt (9), remove the compressor (10) and place it on the control valve side. 10. Disconnect the aftercooler hose.
Engine Right Side 15. Disconnect the aftercooler hose (21). 16. Disconnect the aeration hose (22) and the coolant hose (23).
11. Remove the fuel cooler hose (11), the fuel hose (12), the hose clamp (13), the engine breather hose (14) and the clamp of the muffler drain hose (15).
17. Disconnect the car heater hose (24) and the hose clamp (25). 18. Disconnect the coolant hose (26).
12. Remove the wiring connector (16) and the wiring clamp (17). 13. Disconnect the engine oil filter hose (18).
PC750, 800-7
30-21 (2)
DISASSEMBLY AND ASSEMBLY
ENGINE, PTO AND HYDRAULIC PUMP
19. Reduce the tension of the tension pulley (27) and remove the fan belt (28).
24. Disconnect the servo valve hose (36) and the safety valve hose (37).
20. Disconnect the starter wiring (29) and the ground cable (30).
25. Disconnect the control pump outlet hose (38). 26. Disconnect the outlet hoses (39) and (40) of No. 1 and No. 2 pumps and the drain hoses (41) and (42).
21. Remove the TVC solenoid connector (31) and the clamp, and disconnect the harness from the pump. 22. Disconnect the jet sensor hoses (32) and (33) of No. 1 pump.
27. Disconnect the suction tubes (43) and (44) and the suction hose (45).
23. Disconnect the CO cancel hose (34) and the pilot pressure reducing hose (35).
30-22 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
ENGINE, PTO AND HYDRAULIC PUMP
28. Lift the engine, PTO and pump assembly temporarily and remove the front mounting bolt (46), the rear mounting bolt (47), the left and right mounting bolts.
INSTALLATION
29. Lift the engine, PTO and pump assembly (48) and remove it. a Lift the assembly a little to prevent the fan pulley from interfering, take out the front mount, slide it backward and lift the assembly. 4
•
To install this assembly, reverse the removing procedures. 3 Mounting bolt: 926.1 ± 102.9 Nm {94.5 ± 10.5 kgm}
•
Oil Filling a Fill oil up to the specified level, start the engine to circulate oil throughout the pipe and check the oil level.
•
Water Filling a Fill water up to the specified level, start the engine to circulate coolant throughout the pipe and check the water level.
•
Air Bleeding Bleed air from the main pump referring to the paragraph of "Bleeding Air from Main Pump" in Testing and Adjusting.
Engine, PTO and pump assembly: 26,000 kg
PC750, 800-7
30-23 (2)
DISASSEMBLY AND ASSEMBLY
PTO
REMOVAL AND INSTALLATION OF PTO ASSEMBLY REMOVAL 1. Remove the engine, PTO and hydraulic pump assembly referring to the paragraph of "Removal of Engine, PTO and Hydraulic Pump Assembly".
5. Disconnect the lubrication hoses (7) and (11), the lubrication tubes (4), (5), (6), (8), (9) and (10), and remove the block (12).
2. Lift No. 1 pump assembly (1) and remove it. 4
No. 1 pump assembly: 165 kg
3. Lift No. 2 pump assembly (2) and remove it. 4
No. 2 pump assembly: 150 kg
4. Lift the control, PTO and lubrication pump assembly (3) and remove it. a Take out the suction hose as well at the same time.
6. Lift the PTO assembly (13) and remove it. 4
30-24 (2)
PTO assembly: 500 kg
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
7. Lift the shaft (14) and remove it. 8. Remove the coupling (15). 9. Remove the plate (16).
PTO
INSTALLATION •
To install this assembly, reverse the removing procedures. 3 Bolt: 110.3 ± 12.2 Nm {11.25 ± 1.25 kgm} 3 Bolt: 277.05 ± 31.85 Nm {28.25 ± 3.25 kgm}
PC750, 800-7
30-25 (2)
DISASSEMBLY AND ASSEMBLY
PTO
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY DISASSEMBLY 1. Cover Remove mounting bolts, then using bolt , remove case (3). a Check the number and thickness of the shims, and keep in a safe place.
3. Removal of bearing Using puller , remove bearing from each gear.
ASSEMBLY 2. Gear assembly Remove gear assemblies (5), (6), and (7). a If the gear assembly will not come out, remove nipple (8), then use a puller to remove the gear assembly from the case.
30-26 (2)
a Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Bearings Install bearings (9), (10), (11), (12), and (13) to gears (5), (6), and (7).
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
2. Outer race at case end Press fit outer race (14) to case (15). 3. Nipples, plug Install nipples (8) and plug (16).
4. Gears 1) Install gears (5) and (7). 2) Install gear (6). 3) Rotate gears, check that each gear rotates smoothly, then coat with red lead (minium), and check tooth contact. 2 Bearing: Grease (G2-LI)
PC750, 800-7
PTO
5. Case Fit gasket and install case (3). 2 Gasket: Gasket sealant (LG-1) 3 Bolt: 110.25 ± 12.25 Nm {11.25 ± 1.25 kgm}
a After tightening the bolts, check that the thickness of the gasket is the dimension shown in the diagram below.
30-27 (2)
DISASSEMBLY AND ASSEMBLY
PTO
Adjusting cover shim a Decide the thickness of the cover shim as follows. 1) Without fitting an O-ring, install cover (1), rotate the gear in the direction of the arrow (50 – 60 rpm), and tighten 2 bolts (18) uniformly to 19.6 Nm {2 kgm}. 2) Measure clearances F and G at two places between case (3) and cover (1) with feeler gauge . 3) Calculate clearance F + clearance G, and determine the thickness of the shim according to the following table. Clearance F+G (mm) From
To
0
0.12
0.12
0.32
0.32
0.52
0.52
0.72
0.72
0.92
0.92
1.12
1.12
1.32
1.32
1.52
1.52
1.72
1.72
1.92
1.92
2.12
2.12
2.32
2.32
2.52
2.52
2.72
2.72
2.92
2.92
3.12
3.12
3.32
3.32
3.52
3.52
3.72
3.72
3.92
3.92
4.12
4.12
4.32
4.32
4.52
30-28 (2)
Thickness, part number of shim to use
Overall thickness 21N-30- 21N-33- 21N-38of shim 1250 1260 1270 (mm) (0.1mm) (0.2mm) (0.5mm) 1
1
0.3
2
0.4 1
0.5
1
0.6
1
1
0.7
1
1
0.8
2
1
0.9
2
1.0
2
1.1
1
2
1.2
1
2
1.3
2
2
1.4
3
1.5
3
1.6
1
3
1.7
1
3
1.8
2
3
1.9
4
2.0
4
2.1
1
4
2.2
1
4
2.3
2
4
2.4
2
4
2.5
1
1
1
1
1
1
1
1
1
6. Fit gasket and install cover (19). 2 Gasket: Gasket sealant (LG-1)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
Part No.
DISASSEMBLY
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
1 796-627-1050
Installer
t 1
2 796-627-1030
Push tool
t 1 R
Push-puller
t 1
790-101-2300
• 790-101-2310 • Block
t 1
• 790-101-2350 • Leg
t 2
• 790-101-2360 • Plate
t 2
3 • 02215-11622 • Nut 791-181-1010
Adapter
796T-627-1340 Push tool
790-101-1102
Pump
t 1
Wrench assembly
t 1 N
Spacer
t 1 N
5 01017-52450
Bolt
t 1
01580-12419
Nut
t 1
790-201-2830
Spacer
t 1
790-101-5151
Plate
t 1
790-101-5401
Push tool kit (C)
t 1
6
7
• 790-101-5441 • Plate
t 1
• 790-101-5421 • Grip
t 1
• 01010-51240 • Bolt
t 1
790-101-5001 8
Push tool kit (A)
3. Cover Using forcing screws and eyebolts cover (1).
, remove
4. No. 3 carrier assembly 1) Remove thrust washer (50). 2) Using eyebolts , remove No. 3 carrier assembly (2).
t 1
• 790-101-5151 • Plate
t 1
• 790-101-5061 • Plate
t 1
• 790-101-5021 • Grip
t 1
PC750, 800-7
2. Put travel motor at bottom and set on block of height approx. 350 mm.
t 1 N Q t 1
796-627-1070
Final drive case: Approx. 20 l
t 2
Puller (294kN {30 ton})
J
6
t 2
790-101-2102
4 790-627-1200
1. Draining oil Remove drain plug and drain oil from final drive case.
30-29 (2)
DISASSEMBLY AND ASSEMBLY
3) Disassemble No. 3 carrier assembly as follows. i) Remove mounting bolts (3). ii) Using tool J5, remove holder (4).
iii) Turn over carrier assembly (2) and set to press, then using tool J6, pull out shaft (5) and remove gear assembly (6).
iv) Remove bearing (7) and spacer (8) from gear (6). a If the parts are to be used again, make match marks to prevent any change in the combination with the outer race. v) Remove outer race (9) from gear (6).
30-30 (2)
FINAL DRIVE
5. No. 3 sun gear 1) Remove thrust washer (11) from No. 3 sun gear (10). 2) Remove No. 3 sun gear (10).
6. No. 3 ring gear Using eyebolts , remove No. 3 ring gear (12).
7. Hub assembly 1) Remove lock plate (13). 2) Using tool J4, remove nut (14).
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
3) Using eyebolts , remove hub assembly (15) together with bearing (16) from shaft (41). 4) Remove bearing (16) from hub (49).
5) Remove floating seal (17) from hub (49). a If the seal is to be used again, be careful not to damage the contact surface, and keep in a safe place. 6) Remove outer races (18). 8. Spacer Remove spacer (19) from shaft (41).
FINAL DRIVE
iii) Pull out gear (23) from carrier (27), and remove thrust washer (24) and bearing (25). iv) Remove thrust assembly (26) from carrier (27).
10. No. 2 sun gear Remove No. 2 sun gear (28). 11. No. 2 ring gear Remove No. 2 ring gear (30). 12. Spacer Remove spacer (31).
9. No. 2 carrier assembly 1) Using eyebolts , remove No. 2 carrier assembly (20). 2) Disassemble No. 2 carrier assembly as follows. i) Knock pin (21) into shaft (22). ii) Push shaft (22) from pin side to remove. a Remove the pin from the shaft.
PC750, 800-7
30-31 (2)
DISASSEMBLY AND ASSEMBLY
13. No. 1 carrier assembly 1) Using eyebolts , remove No. 1 carrier assembly (32). 2) Disassemble No. 1 carrier assembly as follows. i) Knock pin (33) into shaft (34). ii) Remove shaft (34) from pin end. a Remove the pin from the shaft.
FINAL DRIVE
14. No. 1 ring gear Remove No. 1 ring gear (39). 15. No. 1 sun gear Remove No. 1 sun gear (40). a However, if the travel motor is removed, the sun gear will fall off when it is put in the posture for disassembly. 16. Thrust washer Remove thrust washer (48) from travel motor. 17. Floating seal Remove floating seal (17). a If the seal is to be used again, be careful not to damage the contact surface, and keep in a safe place.
iii) Pull out gear (35) from carrier (36), then remove thrust washer (37) and bearing (38).
18. Travel motor assembly Turn over shaft (41), and using eyebolts remove travel motor assembly (42).
30-32 (2)
,
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
ASSEMBLY a 1) Clean all parts, check for dirt or damage, and correct all dents and burrs. 2) Coat the bearings and surfaces of all parts with engine oil before installing. 1. Travel motor assembly 1) Fit O-ring, and using eyebolts , install travel motor assembly (42) to shaft (41). a The mounting direction for the motor on the left and right final drive assemblies is opposite, so be careful to distinguish when installing. 2) Turn over travel motor and shaft assembly and set on block (height: approx. 350 mm). 3) Press fit thrust washer (48) of travel motor. After press fitting, confirm that thrust washer (48) is in contact with motor (42). Press fitting force: 225 – 2,646 N {23 – 270 kgf}
FINAL DRIVE
5. No. 1 carrier assembly 1) Assemble No. 1 carrier assembly as follows. a There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. i) Assemble bearing (38) to gear (35), put thrust washer (37) in contact with both ends, then set to carrier (36).
ii)
2. No. 1 sun gear Install No. 1 sun gear (40). 3. No. 1 ring gear Install No. 1 ring gear (39). a Set with the side with the cut outside circumference facing the motor. 4. Spacer Install spacer (31).
PC750, 800-7
Align position of pin holes of carrier and shaft, then tap with a plastic hammer to install shaft (34). a When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. iii) Install pin (33). a Check that the pin groove and protruding part of the pin are not fatigued. If the pin is defective, replace it with a new part. a When assembling the pin again, avoid the position previously used for caulking. a After inserting the pin, caulk the pin portion (marked by arrows) of the carrier. a After assembling the carrier assembly, check that gear (35) rotates smoothly.
30-33 (2)
DISASSEMBLY AND ASSEMBLY
2) Using eyebolts assembly (32).
, install No. 1 carrier
FINAL DRIVE
a There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. iii) Assemble bearing (25) to gear (23), put thrust washer (24) in contact with both ends, then set to carrier (27). iv) Align position of pin holes of carrier and shaft, then tap with a plastic hammer to install shaft (22). a When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer.
6. No. 2 sun gear 1) Press fit thrust washer (29) to No. 2 sun gear (28). 2) Install No. 2 sun gear (28). 7. No. 2 ring gear Install No. 2 ring gear (30).
8. No. 2 carrier assembly 1) Assemble No. 2 carrier assembly as follows. i) Press fit thrust washer (44) to plate (43). ii) Press fit thrust assembly (26) to carrier (27).
30-34 (2)
v) Install pin (21). a Check that the pin groove and protruding part of the pin are not fatigued. If the pin is defective, replace it with a new part. a When assembling the pin again, avoid the position previously used for caulking. a After inserting the pin, caulk the pin portion (marked by arrows) of the carrier. (See Step 5-1)-iii).) a After assembling the carrier assembly, check that gear (33) rotates smoothly. 2) Using eyebolts , install No. 2 carrier assembly (20).
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
9. Spacer Align protruding portion with protruding portion of shaft (41), and install spacer (19). a Set the spacer with the shallow protruding part facing the motor. 10. Hub assembly 1) Floating seal at shaft end Using tool J1, install floating seal (17) to shaft (41). a Remove all oil and grease from the Oring and O-ring contact surface, and dry the parts before installing the floating seal. a After installing the floating seal, check that the angle of the floating seal is within 1 mm. a After installing the floating seal, coat the sliding surface thinly with engine oil.
FINAL DRIVE
2) Inside bearing Shrink fit bearing (16) to shaft (41), or use tool J3 to install.
a When using tool J3, see the drawing below.
3) Outer race at hub end Expand fit outer race (18) to hub (49), or use tool J2 to install. a When using tool J2, see the drawing below.
PC750, 800-7
30-35 (2)
DISASSEMBLY AND ASSEMBLY
4) Floating seal at hub end Using tool J1, install floating seal (17) to hub (49). a For precautions and details of the tool, see Step 10-1). a When turning over the hub, the floating seal will be at the bottom, so install it temporarily with several bolts . 5) Installation of hub assembly Using eyebolts , install hub assembly (15) to shaft (41).
FINAL DRIVE
7) Install nut as follows. i) Set tool J3 in position. ii) Push bearing inner race portion with specified force. a Pushing force: 34.3 – 38.2 kN {3.5 – 3.9 ton} iii) Rotate hub assembly 2 – 3 times to settle bearing.
iv) Measure dimension a in the condition above. 6) Outside bearing Install bearing (16).
v) Measure thickness b of nut (14) as an individual part. vi) Calculate a – b = c. vii) Using tool J4, tighten nut (14) to a point 0 where dimension c = –0.1 mm.
30-36 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
8) Install lock plate (13). a Install the lock plate as shown in the diagram below. 2 Thread of mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 66.2 ± 7.3 Nm {6.75 ± 0.75 kgm}
11. No. 3 ring gear 1) Install O-ring to shaft end. 2) Using eyebolts , install No. 3 ring gear (12). a Align the bolt holes. a Install the ring gear with the machined outside circumference facing up (outside).
12. No. 3 carrier assembly 1) Assemble No. 3 carrier assembly as follows. i) Using tool J7, press fit outer race (9) to gear (46).
PC750, 800-7
FINAL DRIVE
ii)
Assemble bearing (7) and spacer (8) to gear (46), and set to carrier (47). a Align the carrier and bearing and spacer holes securely.
iii) Expand fit shaft (5) or press fit with a press. a Do not move the gear until the tip of shaft (5) enters the carrier. Be particularly careful with the spacer. a After press fitting the pin, check that the gear rotates smoothly. a When press fitting the shaft, be careful of the angle of the shaft. iv) Assemble holder (4) to shaft (5).
v) Tighten bolt (3). 2 Bolt: Thread tightener (LT-2) 3 Bolt: 927 ± 103 Nm {94.5 ± 10.5 kgm} vi) Install thrust washer (50).
30-37 (2)
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
2) Using eyebolts , install No. 3 carrier assembly (2). a Align the low portion (4 places) of spacer (19) and shaft (41) with the carrier assembly holder. a Align the bolt holes also.
13. No. 3 sun gear 1) Install thrust washer (11) to No. 3 sun gear (10). 2) Install No. 3 sun gear (10). a Be careful not to get your fingers caught.
14. Cover Using eyebolts , install cover (1). 2 Mounting surface: Gasket sealant (LG-6) 2 Bolt: Thread tightener (LT-2) 3 Bolt: 980.1 ± 49.5 Nm {100 ± 5 kgm}
30-38 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
SKETCHES OF SPECIAL TOOLS J3 Push tool
PC750, 800-7
30-39 (2)
DISASSEMBLY AND ASSEMBLY
REVOLVING FRAME
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY REMOVAL
6. Pull out pin (7), and move link (8) towards frame.
1. Remove work equipment assembly from chassis. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY. 2. Remove counterweight assembly. For details, see REMOVAL OF COUNTERWEIGHT ASSEMBLY. 3. Disconnect 4 grease tubes (1). 4. Leave 3 or 4 mounting bolts (2) each at front and rear of revolving frame, and remove other mounting bolts. a Start the engine and swing the revolving frame while removing the bolts. a If you do not start the engine, remove the swing motor and use a crane to swing the revolving frame.
7. Revolving frame assembly 1) Fit wires to counterweight mounting frame and boom mount, then sling revolving frame assembly. 2) Remove remaining mounting bolts and lift off revolving frame assembly (9). a Check that the wire is not damaged before using it, and put protective material at the corners. a The revolving frame will tilt towards the operator’s cab, so adjust with a lever block. 4
Revolving frame assembly: Approx. 19,000 kg
5. Disconnect swivel joint top pipes (3), (4), (5), and (6).
INSTALLATION •
Carry out installation in the reverse order to removal. 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 1,814 ± 98 Nm {185 ± 10 kgm} 2 Swing circle top surface: Gasket sealant (LG-6)
30-40 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
SWING MACHINERY
REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY REMOVAL
INSTALLATION
1. Remove the swing motor assembly (1) referring to the paragraph of "Removal of Swing Motor Assembly".
•
To install this assembly, reverse the removing procedures. 3 Mounting bolt: 926.7 ± 102.9 Nm {94.5 ± 10.5 kgm}
•
Oil Filling a Fill oil up to the specified level through the oil filler port. 5
Oil amount in swing machinery case: Approx. 30 l x 2
2. Drain oil from the swing machinery. 6
Oil in case: Approx. 24.5 l x 2
3. Lift the swing machinery assembly (2) temporarily, loosen the mounting bolt (3), screw in the forcing screw, pull out the faucet joint portion and remove the assembly. 4
Swing machinery assembly: 510 kg x 2
PC750, 800-7
30-41 (2)
DISASSEMBLY AND ASSEMBLY
SWING MACHINERY
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY
Part No.
Part Name
790-101-5401 Push tool kit 1 F 2
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
3
2
t 1
• 790-101-5541 • Plate
t 1
• 790-101-5421 • Grip
t 1
• 01010-81240 • Bolt
t 1
790-201-2780 Spacer
t 1
790-201-2880 Spacer
t 1
3 796T-626-1130 Push tool
3. No. 1 carrier assembly 1) Remove thrust washer (2). 2) Remove No. 1 sun gear (3).
t 1 N Q
CEP00206
3) Remove No. 1 carrier assembly (4).
4
DISASSEMBLY 1. Draining oil Loosen drain plug and drain oil from swing machinery case. 6
Swing machinery case: Approx. 24.3 l
2. Cover Remove mounting bolts, then lift off cover (1).
CEP00207
4. Disassemble No. 1 carrier assembly as follows. 1) Push in pin (5) and knock out shaft (6) from carrier (7). a After removing the shaft, remove pin (5). 2) Remove thrust washer (8), gear (9), bearing (10), and thrust washer (11).
1
CEP00205
30-42 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
SWING MACHINERY
5. Ring gear Lift the ring gear (12) and remove it.
7. No. 2 carrier assembly Lift No. 2 carrier assembly (17) and remove it.
6. No. 1 sun gear 1) Remove the thrust washer (13). 2) Remove the button (36) and the spacer (14). 3) Remove No. 1 sun gear (15).
8. Disassemble No. 2 carrier assembly as follows. 1) Push in pin (18), and knock out shaft (19) from carrier (17). a After removing the shaft, remove pin (18). 2) Remove thrust washer (20), gear (21), bearing (22), and thrust washer (23).
19
22
17
20 21 23 18 4) Remove the thrust washer (16). a Remove No. 2 carrier assembly (17) before removing the washer.
CEP00213
9. Pinion shaft assembly 1) Remove bolt (24), then remove holder (25). 2) Remove gear (26).
24 26 25
CEP00214
PC750, 800-7
30-43 (2)
DISASSEMBLY AND ASSEMBLY
SWING MACHINERY
3) Turn over case and pinion assembly, then remove mounting bolts (28) of cover assembly (27).
11. Bearing Using push tool, remove bearing (34) from case (35).
35
34
27
28
CEP00215
4) Turn over case and pinion assembly (29), and set on press stand, then using push tool F3, remove pinion shaft assembly (30) with press. a Set a wooden block under the press, and be careful not to damage the pinion shaft assembly when removing it.
10. Disassemble pinion shaft assembly as follows. 1) Using push tool , remove cover assembly (27) and bearing (31) from shaft (32). 2) Remove oil seal (33) from cover (27).
33
CEP00220
ASSEMBLY a Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Bearing Using push tool F2, press fit bearing (31) to case (35).
2. Cover assembly 1) Using push tool F1, press fit oil seal (33) to cover (27). 2 Outside circumference of oil seal: Gasket sealant (LG-6) a Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when press fitting.
27 31 32 27 CEP00218
30-44 (2)
CEP00219
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
SWING MACHINERY
2) Fit cover assembly (27) to case (35), and tighten mounting bolts (28). 2 Cover mounting surface: Gasket sealant (LG-6) 2 Lip of oil seal: Grease (G2-LI) a Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when press fitting.
27
2) Bearing Using tool F3, press fit bearing (34). a Push the bearing inner race and outer race at the same time when press fitting. Do not push only the inner race when press fitting. a After press fitting the bearing, check that the case rotates smoothly.
28 35
CEP00223
3. Case assembly 1) Set case assembly (35) to shaft (32), then using push tool , press fit bearing inner race portion. a When setting the case assembly to the shaft, be extremely careful not to damage the oil seal.
3) Gear, holder Assemble gear (26), then fit holder (25) and tighten bolt (24). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 385 ± 42 Nm {39.25 ± 4.25 kgm}
24 26 25
CEP00214
PC750, 800-7
30-45 (2)
DISASSEMBLY AND ASSEMBLY
SWING MACHINERY
4. Assemble No. 2 carrier assembly as follows. a There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. 1) Assemble bearing (22) to gear (21), fit top and bottom thrust washers (23) and (20) and set gear assembly to carrier (17).
22
5. No. 2 carrier assembly Lift No. 2 carrier assembly (17) and install it. a Adjust the positions of the 4 gear shaft ends before installing it.
17
20 21 23
h CEP00226
6. No. 2 sun gear 1) Set the thrust washer (16). a Be sure to set the washer before installing No. 2 carrier assembly (17).
2) Align position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (19). a When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. 3) Insert pin (18). a After inserting the pin, caulk the pin portion of the carrier. a After assembling the carrier assembly, check that gear (21) rotates smoothly.
21
18
30-46 (2)
19
2) Assemble No. 2 sun gear in No. 2 carrier. 3) Install the spacer (14) and the button (36). 4) Install the thrust washer (13).
CEP00227
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
7. Ring gear Lift the ring gear (12) and install it. a Apply gasket sealant to the periphery of the oil level check hole only. 2 Mating face of ring gear and case: Gasket sealant (LG-6)
8. Assemble No. 1 carrier assembly as follows. a There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. 1) Assemble bearing (10) to gear (9), fit top and bottom thrust washers (8) and (11) and set gear assembly to carrier (7).
SWING MACHINERY
2) Align position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (6). a When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. 3) Insert pin (5). a After inserting the pin, caulk the pin portion of the carrier. a After assembling the carrier assembly, check that gear (9) rotates smoothly.
9. No. 1 carrier assembly Install No. 1 carrier assembly (4).
4
CEP00207
10. No. 1 sun gear 1) Assemble No.1 sun gear (3) to carrier assembly. 2) Install thrust washer (2).
3
2
CEP00206
PC750, 800-7
30-47 (2)
DISASSEMBLY AND ASSEMBLY
SWING MACHINERY
11. Cover Install cover (1). 2 Cover mounting surface: Gasket sealant (LG-6) 3 Mounting bolt: 1st pass: 98 Nm {10 kgm} 2nd pass: 105 ± 5°
1
CEP00205
12. Refilling with oil Tighten drain plug and add oil through oil filler. 5
Swing machinery case: Approx. 24.3 l
SKETCHES OF SPECIAL TOOLS F3 Push tool
30-48 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
SWING CIRCLE
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY REMOVAL
INSTALLATION
1. Remove revolving frame assembly. For details, see REMOVAL OF REVOLVING FRAME ASSEMBLY. 2. Remove grease tubes (1). 3. Remove mounting bolts (2).
•
Carry out installation in the reverse order to removal. 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 1,715 ± 195 Nm {175 ± 20 kgm} 2 Swing circle mounting surface: Gasket sealant (LG-6) a Amount of grease (G2-LI) in oil bath: Approx. 65 l a Coat inside teeth with grease (G2-LI). a Apply about 10 l of grease (G2-LI) to the internal tooth. a Install so that the inner race soft zone is facing the left side of the chassis.
4. Pass round bar through revolving frame mounting bolt holes, fit wire, then lift off swing circle assembly (3). 4
Swing circle assembly: 1,263 kg
5. Remove seal (4).
PC750, 800-7
30-49 (2)
DISASSEMBLY AND ASSEMBLY
TRACK SHOE
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY
M
Part No.
1
3. Using tool M, pull out master pin.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
791-680-9501
Remover, installer
t 1
790-101-4300
Cylinder (1,471 kN {150 ton})
t 1
790-101-4200
Puller (294 kN {30 ton})
t
790-101-1102 Pump
t
2 790-331-1100 Wrench
t
4. Fit block or hydraulic jack (10 ton) under shoe at idler end, then remove guide pin .
REMOVAL 1. Positioning master pin a Move the master pin so that it is midway between the idler and the carrier roller. The track shoe is opened to the rear, so be sure that there is enough space. 2. Loosen track shoe tension. k Never loosen lubricator (1) more than one turn. a If the track tension is not relieved even when the lubricator is loosened, move the machine backwards and forwards.
30-50 (2)
5. Raise tip of track shoe with crane, and move machine slowly to rear to open track shoe assembly (3).
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
TRACK SHOE
INSTALLATION •
Carry out installation in the reverse order to removal.
a Adjust the track shoe tension. For details, see TESTING AND ADJUSTING, Adjusting track shoe tension. 3 Lubricator: 73.5 ± 14.7 Nm {7.5 ± 1.5 kgm}
a Assemble spacer (4) and washer (5) to the link, connect to bottom link, then install guide pin.
PC750, 800-7
30-51 (2)
DISASSEMBLY AND ASSEMBLY
ONE LINK IN FIELD
DISASSEMBLY AND ASSEMBLY OF ONE LINK IN FIELD
1
2
3
N 4
Q’ty New/Remodel Sketch
Part Name
Necessity
Part No.
791-680-9580 Adapter
t 1
791-680-9590 Guide
t 1
01010-52760 Bolt
t 2
01010-51440 Bolt
t 2
790-101-1102 Pump
t 1
790-101-4300 Cylinder (*1)
t 1
8 791-680-5580 Guide
t 1
791-685-9510 Frame
t 1
791-685-9510 Frame
t 1
791-685-9520 Frame
t 1
791-685-9520 Frame
t 1
791-685-9530 Rod
t 1
791-685-9530 Rod
t 1
791-685-9550 Nut
t 1
791-685-9540 Rod
t 1
791-685-9560 Bolt
t 4
791-685-9550 Nut
t 3
791-680-9570 Adapter
t 1
791-685-9560 Bolt
t 4
01010-51030 Bolt
t 1
9 791-126-0150 Adapter
t 1
04530-12030 Eyebolt
t 1
01010-51030 Bolt
t 1
790-101-1102 Pump
t 1
791-685-9620 Extension
t 1
790-101-4300 Cylinder (*1)
t 1
791-680-5542 Adapter
t 1
791-685-9540 Rod
t 1
791-680-5560 Guide
t 1
791-685-9550 Nut
t 3
790-101-1102 Pump
t 1
791-685-9510 Frame
t 1
790-101-4300 Cylinder (*1)
t
791-685-9520 Frame
t 1
791-685-9510 Frame
t 1
791-685-9530 Rod
t 1
791-685-9520 Frame
t 1
791-685-9550 Nut
t 1
791-685-9530 Rod
t 1
791-685-9560 Bolt
t 4
791-685-9540 Rod
t 1
791-126-0150 Adapter
t 1
791-685-9550 Nut
t 3
791-685-9560 Bolt
t 4
791-126-0150 Adapter
t 1
5 791-680-5520 Guide
t 1
5 790-101-4300 Cylinder (*1) 6
7
N
10
t 1
790-101-1102 Pump
t 1
790-101-4200 Pulley (*2)
t 1
791-680-5542 Adapter
t 1
791-632-1110 Adapter
t 1
791-126-0140 Pusher
t 1
791-680-9570 Adapter
t 1
01010-51030 Bolt
t 1
01010-51030 Bolt
t 1
791-685-9620 Extension
t 1
04530-12030 Eyebolt
t 1
791-680-5560 Guide
t 1
791-685-9620 Extension
t 1
791-632-1110 Adapter
t 1
791-101-1102 Pump
t 1
791-680-9630 Adapter
t 1
30-52 (2)
Symbol
Part Name
Q’ty New/Remodel Sketch
Part No.
Necessity
Symbol
SPECIAL TOOLS
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
ONE LINK IN FIELD
10
Part Name
Q’ty New/Remodel Sketch
Part No.
Necessity
Symbol
DISASSEMBLY
790-101-1102 Pump
t 1
790-101-4300 Cylinder (*1)
t 1
11 790-680-1520 Guide
t 1
791-685-9510 Frame
t 1
791-685-9520 Frame
t 1
791-685-9530 Rod
t 1
791-685-9540 Rod
t 1
791-685-9550 Nut
t 3
791-685-9560 Bolt
t 4
12 791-126-0150 Adapter
t 1
N
13
791-680-5560 Guide
t 1
791-680-9570 Adapter
t 1
01010-51030 Bolt
t 1
791-680-1520 Guide
t 1
790-101-1102 Pump
t 1
790-101-4300 Cylinder (*1)
t 1
790-101-1102 Pump
t 1
790-101-4200 Pulley (*2)
t 1
791-680-9501 14
Remover (kit), installer
t 1
790-101-1102 Pump
t 1
790-101-4200 Pulley (*2)
t 1
790-101-4300 Cylinder (*1)
t 1
1. Using two bolts (2), install tool N1 (adapter, guide, bolt) to link (1). a It is also possible to use two track bolts for bolt (2).
2. Assemble tool N2 (pump, cylinder 1471 kN {150t}) and tool N3 (frame, rod, adapter, bolt x 1, eyebolt), then raise chassis and set on track.
3. Insert rod of tool N4 from cylinder end, and install with two nuts. a Pass the rod through the hole in link (1) to install.
(*1) : 1,471 kN {150 ton} (*2) : 294 kN {30 ton}
PC750, 800-7
30-53 (2)
DISASSEMBLY AND ASSEMBLY
4. Set tool N5 (adapter, guide, pusher) in position, then apply hydraulic pressure and remove pin (3). When the cylinder reaches the end of its stroke, insert extension N5 between the adapter and guide, and repeat the operation.
5. Set tool N6 (294 kN {30 ton} puller) and spacer to center of roller tread of link to be disassembled, then apply hydraulic pressure to puller and open link 5 – 6 mm.
ONE LINK IN FIELD
ASSEMBLY 1. Assemble link sub-assembly. 1) Set tool N7 to end face of link, then press fit bushing (1). 2) Set tool N7 to end face of link (pin end), and press fit pin (2).
2. Set link sub-assembly (3) on link to be connected.
3. Set link (4) on opposite side, and support with tool N8 (guide).
30-54 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
4. Set tools N9 and N10 in same way as for operation to remove pin, then use tool N9 (adapter, extension, guide, adapter, bolt) for press fitting pin, and tool N10 (extension, guide, adapter, bolt) for press fitting bushing, and press fit in turn.
ONE LINK IN FIELD
7. Set tool N9 at pin (7) end, then use tool N12 (adapter, bolt, and guide) to press fit pin (7).
2 Pin press-fitting hole in link: Gasket sealant (LG-1)
5. Use tool N13 (294 kN {30t} puller) in same way as when disassembling, and push open link (5) at bushing end.
6. Set link (6) at pin end to link (5) at bushing end, connect with tool N11 (guide), then remove tool N13 (puller).
PC750, 800-7
30-55 (2)
DISASSEMBLY AND ASSEMBLY
IDLER
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY REMOVAL 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove idler assembly (1). a Pull out the idler assembly, then lift off the idler and adjustment cylinder. 4
Idler assembly: 500 kg
INSTALLATION •
Carry out installation in the reverse order to removal.
30-56 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
IDLER
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY
L
Part No.
5. Remove shaft (8) from idler.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
1 790-201-2680 Plate
t 1
2 796-675-1510 Instaler
t 1
DISASSEMBLY 1. Remove plug and drain oil. 6
6. Remove floating seal (4) from idler (7).
Idler : Approx. 550 – 630 cc
2. Set idler assembly (1) on block , remove bolt and nut (2), then remove support (3). 3. Remove floating seal (4).
7. Remove bushings (9) and (10) from idler.
4. Turn over idler assembly, remove bolt and nut (5), then remove support (6).
PC750, 800-7
30-57 (2)
DISASSEMBLY AND ASSEMBLY
8. Remove floating seals (4) from supports (3) and (6).
IDLER
ASSEMBLY a Clean all parts, and check for dirt or damage. 1. Using tool L2, assemble floating seals (4) to supports (6) and (3).
2. Using tool L1, press fit bushings (10) and (9) to idler.
3. Using tool L2, assemble floating seal (4) to idler.
30-58 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
4. Turn over idler and using tool L2, assemble floating seal (4).
IDLER
8. Turn over idler, and assemble support (3) to shaft. a Align the groove in the support with the groove in the shaft when assembling. 9. Install bolt and nut (2), and secure support (3).
5. Install shaft (8) to idler. a Assemble the shaft so that the direction of the oil filler plug is as follows. • Right side of machine: Facing outside • Left side of machine: Facing inside
10. Using tool, add oil to specified level, then tighten plug. 5 Idler: 550 – 630 cc (GO140B) 3 Plug: 210.7 ± 29.4 Nm {21.5 ± 3 kgm}
6. Assemble support (6) to shaft. a Align the groove in the support with the groove in the shaft when assembling. 7. Install bolt and nut (5), and secure support (6).
PC750, 800-7
30-59 (2)
DISASSEMBLY AND ASSEMBLY
IDLER ADJUSTMENT CYLINDER
DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY DISASSEMBLY
ASSEMBLY
1. Remove plunger assembly (1).
1. Install wear ring (6) to plunger (2).
2. Remove snap ring (3), then remove packing (4), backup ring (5), and wear ring (6) from plunger (2).
2. Assemble backup ring (5) and packing (4) to plunger (2), and install snap ring (3).
3. Remove dust seal (7).
3. Fill inside with grease (G2-LI), then assemble plunger assembly (1) in piston. 4. Install dust seal (7).
30-60 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY REMOVAL
a The coil portion of the recoil spring assembly is hooked on the rib inside the track frame, so prepare a special tool for disassembly. 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY.
INSTALLATION •
Carry out installation in the reverse order to removal. a To check that the spring is securely fitted inside the track frame, check through the side hole on the inside (at the 5th track roller from the front).
2. Remove idler assembly. For details, see REMOVAL OF IDLER ASSEMBLY. 3. Recoil spring assembly 1) Remove No. 2 and No. 3 track roller assemblies. For details , see REMO VAL OF TRACK ROLLER ASSEMBLY. 2) After removing track roller assembly, install tool . a When making tool , see Fig. 1. a Lower the track frame on top of the track shoe. 3) Using eyebolts (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out recoil spring assembly (1) and lift off. 4
Recoil spring assembly: 250 kg
PC750, 800-7
30-61 (2)
DISASSEMBLY AND ASSEMBLY
Fig. 1 (for tool
30-62 (2)
RECOIL SPRING
)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
M 3
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
791-685-8501 Compressor
t 1
791-635-3160 Extension
t 1
796-630-1110 Plate
t 1
01010-51640 Bolt
t 2
791-630-1120 Spacer
t 1
790-101-1600
Cylinder (686 kN {70 ton})
t 1
790-010-1102 Pump
t 1
796-630-1110 Plate
t 1
2. Apply hydraulic pressure slowly to compress spring, then remove lock plate, and remove nut (2).
3. Release hydraulic pressure gradually to relieve tension of spring, then remove recoil spring assembly (1) from tool M3. 4. Remove rear pilot (4) and rod (5) from spring (3).
DISASSEMBLY 1. Set recoil spring assembly (1) to tool M3. k The recoil spring is under large installed load, so be sure to set the tool properly. Failure to do this is dangerous. a Installed load of spring: 490 kN {50 ton}
PC750, 800-7
30-63 (2)
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
ASSEMBLY 1. Install tool D1 to tip of rod (5). a Tool M3 is to prevent damage to the thread when inserting the rear pilot.
2. Install rod (5) to spring (3). Assemble rear pilot (4), and set to tool M3. k The recoil spring is under large installed load, so be sure to set the parts properly. Failure to do this is dangerous. 3. Apply hydraulic pressure slowly to compress spring so that installed length of spring is standard dimension. a Installed length "a" of spring: 1,290 mm
4. Fit nut (2) and secure with lock plate. 5. Release hydraulic pressure gradually to relieve tension of spring, then remove recoil spring assembly (1) from tool M3.
30-64 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY REMOVAL
INSTALLATION
1. Loosen the track shoe a bit referring to the paragraph of "Tension Adjustment of Track Shoe" in Testing and Adjusting. 2. Use the hydraulic jack shoe.
•
To install this assembly, reverse the removing procedures. 3 Carrier roller mounting bolt: 549 ± 58 Nm {56 ± 6 kgm}
to push up the track
3. Remove 4 pieces of the mounting bolt (1).
4. Lift the carrier roller assembly (2) and remove it. a Take out the carrier roller assembly as far as it does not drop. 4
Carrier roller assembly: 52 kg
PC750, 800-7
30-65 (2)
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY
L
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
3 790-1101-5401 Push tool kit
t 1
4 796T-630-1130 Push tool
t 1
5 796T-630-1140 Adapter
t 1 N Q
6 791-670-1010 Installer
t 1
5. Remove the assembly of the roller (4) and the floating seal (5) on the support (2). 6. Remove the floating seal (5) from the support (2). 7. Remove the bearing (6) from the support (2).
DISASSEMBLY 1. Remove the plug and drain oil. 6
Carrier roller assembly: Approx. 300 – 350cc
2. Set the carrier roller assembly (1) on the press base. a Since the assembly will drop if the support (2), the shaft (3) and the roller (4) are removed from the roller (1), set a pedestal below the roller.
8. Remove the floating seal (5) from the roller (4). 9. Remove the bearing (6) from the shaft (3) by using the tool L3.
3. Push the shaft end face with the press and install the assembly of the support (2), the shaft (3) and the roller (4). a Remove the floating seal (5) from the support (2). 4. Push the end face of the shaft (3) and remove the shaft (3), the bearing (6) and the spacer (8) from the roller (4).
30-66 (2)
10. Remove the bearing outer race (7) from the support (2).
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
ASSEMBLY 1. Press fit the bearing outer race (7) in the both sides of the support (2) by using the tool L3. 2. Press fit the bearing (6) in the shaft (3) by using the tool L3.
3. Mount the floating seal (5) on the roller (4) by using the tool L4. a Make sure that the seal is inclined less than 1 mm. a Clean the O-ring and the O-ring contacting surface to degrease them completely and dry them.
CARRIER ROLLER
10. Press fit the roller, in which the floating seal (5) was assembled, in the shaft (3). a Press fit the roller (4) to the shaft end face and press fit the roller finally by using the tool L5. a Secure more than 18 ton of press fitting force between the shaft and each roller.
11. Assemble the carrier roller assembly (1) and fill it with oil. 5
Lubricating oil: 300 – 350cc (GO140)
12. After filling it with oil, plug the assembly. 3 Plug: 206 ± 49 Nm {21 ± 5 kgm}
4. Set the roller (4), on which the floating seal (5) was set, on the tool L5. 5. Press fit the shaft (3), to which the bearing (6) was assembled, in the roller (4). 6. Assemble the floating seal (5) in the support (2) and mount them so that the bearing (6) aligns to the bearing outer race (7). 7. Insert the spacer (8) in the shaft. 8. Press fit the bearing (6) in the shaft (3). 9. Mount the floating seal (5) on the support (2).
PC750, 800-7
30-67 (2)
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
SKETCHES OF SPECIAL TOOLS L-5 Adapter
30-68 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY
L 7
Part No.
4. Using tool L7, remove track roller assembly (2).
Part Name
4
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
791-401-1700 Lifting tool
t 1
791-401-1761 Adapter
t 1
791-401-1540 Shackle
t 2
791-401-1770 T-bolt
t 2
Track roller assembly (S flange): 140 kg
REMOVAL 1. Loosen track shoe tension. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove track roller guard (1). 4
Track roller guard: 170 kg
INSTALLATION •
Carry out installation in the reverse order to removal. 3
Roller mounting bolt: 137.2 ± 98 Nm {140 ± 10 kgm}
3. Using work equipment, push up track frame on side which is to be removed. k After jacking up the chassis, set a block on the track shoe.
PC750, 800-7
30-69 (2)
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
8 791-580-1520 Installer
t 1
9 790-201-2670 Plate
t 1
791-601-1000 Oil pump
L 10
4. Pull out roller (4) from shaft (5). a It is filled with 280 – 310 cc. of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty. 5. Remove floating seal (6) on opposite side from roller (4) and collar (8).
5
6
t 1
or
4
791-646-8002 Oil lubricator
t 1
790-701-3000 Seal checker
t 1
4
CEP00087
DISASSEMBLY 1. Remove plug and drain oil. a Rotate the shaft while draining the oil. 6
Track roller: Approx. 420 – 480 cc
CEP00088
6. Remove pin (7), then remove collar (8) from shaft (5). 7. Remove bushings (9) and (10) from roller (4).
2. Remove pin (1), then remove collar (2).
9, 10 5 6 8 4 7
CEP00089
CEP00090
3. Remove floating seal (3) from collar (2) and roller (4).
3 3
4
1 2
30-70 (2)
CEP00085
CEP00086
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
ASSEMBLY
TRACK ROLLER
2. Assemble collar (8) to shaft (5), and install pin (7).
4. Using tool L9, install floating seals (6) and (3) to roller (4). a For details of the precautions when installing floating seals (6b) and (6d), and (3b) and (3d), see the precautions marked a for Step 3.
3. Using tool L9, install floating seal (6) to shaft (5).
5. Assemble shaft (5) to roller (4).
1. Using tool L10, press fit bushings (9) and (10) to roller (4).
5
4
CEP00096
a When assembling the floating seal, clean the contact surface of O-ring (6c) and floating seal (6a), remove all grease and oil, and dry it. Make sure that no dirt or dust sticks to the contact surface of the floating seal. a After inserting the floating seal, check that the angle of the seal is less than 1 mm and that the protrusion of the seal is within a range of 5 – 7 mm.
6. Turn over roller (4) and shaft (5) assembly. 7. Using tool L9, install floating seal (3) to collar (2). a For details of the precautions when installing floating seals (3a) and (3c), see the precautions marked a for Step 3.
4
5
CEP00097
8. Assemble collar (2) to shaft (5), and install pin (1).
2
1
5 CEP00099
PC750, 800-7
30-71 (2)
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
9. Using tool L10, apply standard pressure to roller oil filler port, and check for leakage of air from seal. a Standard pressure: 0.1 MPa {1 kg/cm2} a Method of checking The standard pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down.
10. Using tool L10, fill track roller assembly with oil, then tighten plug (11). 5
Track roller oil: 280 – 310 cc (EO30-CD) 3 Plug: 14.7 ± 4.9 Nm {1.5 ± 0.5 kgm}
11
CEP00202
30-72 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY REMOVAL k
Swing the frame to bring the hydraulic tank to the intermediate position between the left and the right track shoes. k Lower the work equipment completely to the ground and stop the engine. Loosen the cap of the hydraulic tank slowly to release internal pressure of the hydraulic tank. a Place counter marks on all hoses before disconnecting them. a Stop all disconnected tubes and hoses with plug.
4. Remove 3 pieces of the wiring clamp (3) and disconnect the wiring connector (4).
1. Drain oil from the hydraulic tank. 6
Hydraulic tank : 650 l
2. Remove the control valve cover (1).
5. Loosen 3 pieces of the mounting bolt (5) of the pilot relief valve assembly and remove the valve assembly from the hydraulic tank without disconnecting the hose.
3. Remove the control valve cover bracket (2). 6. Loosen the drain filter assembly bracket bolt (6) and remove it from the hydraulic tank. 7. Loosen the PTO lubricating oil filter bracket bolt (7) and remove it from the hydraulic tank.
PC750, 800-7
30-73 (2)
DISASSEMBLY AND ASSEMBLY
8. Disconnect the return filter inlet hose (8) and the outlet hose (9) from the control valve.
HYDRAULIC TANK
12. Lift the hydraulic tank assembly (14) and remove it. 4
Hydraulic tank assembly: 474 kg
9. Disconnect the hose (10) from the oil cooler. 10. Disconnect the hoses (11) and (12) from the return filter to the oil cooler.
INSTALLATION •
To install this assembly, reverse the removing procedures. 2 Mounting bolt: Thread tightener (LT-2) 3 Hydraulic tank mounting bolt: 549 ± 58 Nm {56 ± 6 kgm}
•
Filling (hydraulic tank) with oil Circulate oil throughout the pipe and then check the oil level again.
•
Air Bleeding Bleed air referring to the paragraph of "Bleeding Air from Each Part" in Testing and Adjusting.
11. Disconnect the suction tube (13) below the hydraulic tank.
30-74 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
MAIN PUMP (NO. 1 PUMP)
REMOVAL AND INSTALLATION OF MAIN PUMP (NO. 1 PUMP) ASSEMBLY
L
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
1 796-770-1301 Oil stopper
t 1
2
t 1
209-60-71130 Rod assembly
3 790-101-5001 Push tool kit
t 1
4 • 790-101-5151 • Plate
t 1
5 • 790-101-5021 • Grip
t 1
6
t 1
01010-50816 Bolt
REMOVAL k
Lower the work equipment completely to the ground and stop the engine. Loosen the cap of the hydraulic tank slowly to release internal pressure of the hydraulic tank. k Disconnect the (–) terminal of the battery. a Attach a tag to each hose so that it can be connected to the correct position. 1. Remove the strainer of the hydraulic tank and stop oil flow by using the tool S. a When the tool S is not used, remove the drain plug and drain oil from the hydraulic tank and the pipes. 6
7. Disconnect the hoses (9), (10), (11), (13) and (14). 8. Disconnect the suction tube (12).
Hydraulic tank: Approx. 500 l
2. Open the engine hood and the pump rear cover and remove the pump upper cover. 3. Remove the TVC solenoid connector (1). 4. Disconnect the hose (2). 5. Disconnect the hoses (3), (4) and (5). 6. Disconnect the hoses (6), (7) and (8).
PC750, 800-7
30-75 (2)
DISASSEMBLY AND ASSEMBLY
MAIN PUMP (NO. 1 PUMP)
9. Lift the main pump (No. 1 pump) assembly temporarily, remove the mounting bolt and remove the assembly. 4
Main pump assembly: 165 kg
INSTALLATION •
To install this assembly, reverse the removing procedures.
•
Filling (the hydraulic tank) with oil a Fill oil up to the specified level through the oil filler port, start the engine to circulate oil throughout the pipes and check the oil level again.
•
Bleeding Air a Bleed air from each part referring to the paragraph of "Testing and Adjusting".
30-76 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
MAIN PUMP (NO. 2 PUMP)
REMOVAL AND INSTALLATION OF MAIN PUMP (NO. 2 PUMP)
L
Part No.
3. Separate the hoses (1), (2), (3) and (4).
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
t 1
1
796-770-1301 Oil stopper
2
209-60-71130 Rod assembly t 1
3
790-101-5001 Push tool kit
t 1
4 • 790-101-5151 • Plate
t 1
5 • 790-101-5021 • Grip
t 1
6
t 1
01010-50816 Bolt
REMOVAL k
Lower the work equipment to touch the ground completely and stop the engine. After that, slowly loosen the cap of the hydraulic oil tank to release the inside pressure of the hydraulic oil tank. k Separate the (–) terminal of the battery. a Put tags, etc. to each piping so that the mounting position may not be mistaken. 1. Remove the hydraulic oil tank strainer and stop the oil using the tool S. a In case the tool S is not used, remove the drain plug to drain oil from the inside of the hydraulic oil tank and from the inside of the piping. 6
4. Separate the hoses (5) and (6) and suction tube (7).
Hydraulic oil tank: Approx. 500 l
2. Open the engine hood and the rear cover of the pump. After that, remove the upper cover of the pump.
PC750, 800-7
30-77 (2)
DISASSEMBLY AND ASSEMBLY
MAIN PUMP (NO. 2 PUMP)
5. By the hanging bolt, temporarily hang the main pump (No. 2 pump) assembly (8) and remove the mounting bolt to remove the pump. 4
Main pump assembly: 150 kg
INSTALLATION •
Installation shall be made in the reversed procedure of the removal procedure.
•
Filling the oil (Hydraulic oil tank) a Fill the oil to the stipulated level from the oil filler port, start the engine to circulate the oil inside the piping and, after that, re-check the oil level.
•
Air Bleeding a Carry out air bleeding of each section referring to the section "Testing and adjusting".
30-78 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL AND INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL REMOVAL 1. Remove main pump assembly. For details, see REMOVAL OF MAIN PUMP ASSEMBLY. 2. Remove cover (1). a Be careful not to lose shims (2) and (3).
INSTALLATION •
Carry out installation in the reverse order to removal. 2 Lip of oil seal: Grease (G2-LI) 2 Coat the outside circumference of the oil seal thinly with grease (G2-LI), then press fit. a Using tool , press fit oil seal (4).
3. Remove oil seal (4) from cover (1).
PC750, 800-7
30-79 (2)
DISASSEMBLY AND ASSEMBLY
CONTROL AND PTO LUBRICATION PUMP
REMOVAL AND INSTALLATION OF CONTROL AND PTO LUBRICATION PUMP ASSEMBLY
S
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
t 1
1
796-770-1301 Oil stopper
2
209-60-71130 Rod assembly t 1
3
790-101-5001 Push tool kit
t 1
4 • 790-101-5151 • Plate
t 1
5 • 790-101-5021 • Grip
t 1
6
t 1
01010-50816 Bolt
REMOVAL k
Lower the work equipment to touch the ground completely and stop the engine. After that, slowly loosen the cap of the hydraulic oil tank to release the inside pressure of the hydraulic oil tank. k Separate the (–) terminal of the battery. a Put tags, etc. to each piping so that the mounting position may not be mistaken.
INSTALLATION •
Installation shall be made in the reversed procedure of the removal procedure.
•
Filling the oil (Hydraulic oil tank) a Fill the oil to the stipulated level from the oil filler port, start the engine to circulate the oil inside the piping and, after that, re-check the oil level.
•
Air Bleeding a Carry out air bleeding of each section referring to the section "Testing and adjusting".
1. Remove the hydraulic oil tank strainer and stop the oil using the tool S. a In case the tool S is not used, remove the drain plug to drain oil from the inside of the hydraulic oil tank and from the inside of the piping. 6
Hydraulic oil tank: Approx. 500 l
2. Open the rear cover of the pump. 3. Remove the suction hose and tube. 4. Separate the delivery port hoses (3) and (4). 5. Remove the control and PTO lubrication pump assembly (6). 4
30-80 (2)
Pump assembly: 35 kg
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
MAIN RELIEF VALVE
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY DISASSEMBLY 1. Remove sleeve assembly (1) from sleeve (2). 2. Remove springs (3) and (4), pistons (5) and (6), and sleeve (7). 3. Disassembly of sleeve assembly (1) a Do not disassemble except when replacing parts. Measure the protrusion of sleeves (9) and (12) when disassembling. a Loosen locknut (8), and remove sleeve (9) and piston (10). a Loosen locknut (11), and remove sleeve (12), spring (13), and piston (14) from sleeve (15).
ASSEMBLY 1. Assembly of sleeve assembly (1) a Set sleeves (12) and (9) to the protrusion measured when disassembling. After installing to the control valve, adjust the relief pressure. For details, see TESTING AND ADJUSTING. 1) Assemble piston (14) and spring (13) to sleeve (15), then screw in sleeve (12) and tighten locknut (11). 3 Locknut: 107.8 ± 14.7 Nm {11 ± 1.5 kgm} 2) Assemble piston (10) and sleeve (9) to sleeve (12), and tighten locknut (8). 3 Locknut: 85.75 ± 7.35 Nm {8.75 ± 0.75 kgm} 2. Assemble sleeve (7), pistons (6) and (5), and springs (4) and (3) to sleeve (2). 3. Install sleeve assembly (1). 3 Sleeve: 186.2 ± 9.8 Nm {19 ± 1 kgm}
PC750, 800-7
30-81 (2)
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY REMOVAL k
Lower the work equipment to touch the ground completely and stop the engine. After that, slowly loosen the cap of the hydraulic oil tank to release the inside pressure of the hydraulic oil tank. k Referring to the section Releasing the remaining pressure from the hydraulic circuit" in the "Testing and adjusting", release the remaining pressure from the hydraulic circuit. a Put the counter mark before separating the hose and tube. a Put the plug to the hose and tube.
3. Separate the PPC hose (3) of the pilot change over valve and the hose (4) between the control valve. After that, remove the valve assembly (5).
1. Remove the control valve cover (1). 4. Remove the tubes (6) and sensor (7) between t h e m a i n p u m p a n d r e m o v e t h e t u b e (8 ) between the 4-spool control valve and the 5spool control valve.
2. Remove the control valve cover bracket (2).
30-82 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
a 4-spool control vale 5. Separate the 14 pcs. of the PPC hoses (9). 6. Separate each tube of the travel (10), boom (11), bucket (12) and arm (13).
CONTROL VALVE
a 5-spool control vale 9. Separate the LH swing motor hose (17). 10. Separate the RH swing motor hose (18). 11. Remove the tube clamp (19) and tube (20).
7. Separating the lower side back pressure compensation valve hose. Separate the tube (14) between the 5-spool control valve.
12. Remove the piping brackets (21) and (22).
13. Separate each tube of the boom (23), swing (24), arm (25), bucket (26) and travel (27). 8. Temporarily hang the 4-spool control valve and remove the 3 pcs. of the mounting bolts (15) to remove the control valve assembly (16). 4
4-spool control valve assembly, RH: 250 kg
PC750, 800-7
14. Separating the lower side back pressure compensation valve hose. Separate the sensor (7). Separate the tube (28) between the 4-spool control valve. 15. Separate the 16 pcs. of the PPC hoses (29).
30-83 (2)
DISASSEMBLY AND ASSEMBLY
16. Temporarily hang the 5-spool control valve and remove the 3 pcs. of the mounting bolts (30) to remove the control valve assembly (16). 4
5-spool control valve assembly, RH: 250 kg
CONTROL VALVE
INSTALLATION •
Installation shall be made in the reversed procedure of the removal procedure.
a Install the tube (1) and adjust the mounting position of the valve. After that, fasten the valve assembly mounting bolt (2). 3 Control valve assembly mounting bolt: 279 ± 29 Nm {28.5 ± 3 kgm}
a Referring to the section "Testing and adjusting", confirm the hydraulic pressure of the work equipment circuit, travel circuit and swing circuit and confirm the speed. •
30-84 (2)
Filling the oil (Hydraulic oil tank) a Fill the oil to the stipulated level from the oil filler port, start the engine to circulate the oil inside the piping and, after that, re-check the oil level.
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE ASSEMBLY (WORK EQUIPMENT)
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (WORK EQUIPMENT) DISASSEMBLY
a The operation described below is for the right 4spool control valve (with straight-travel valve), but the procedure is basically the same for the left 5-spool control valve also. 1. Remove mounting bolts, then remove straighttravel valve assembly (2). 2. Disassemble straight-travel valve assembly as follows. 1) Remove cover (3). 2) Pull out plug (4), and remove backup ring (5). 3) Remove sleeve (6), and pull out piston (7), spool (8), and spring (9). 4) Remove plug (10), and pull out spring (11) and check valve (12). 5) Loosen nut (13) and remove sleeve (14). 3. Remove spring (15) and check valve (16). 4. Remove seat (17), spring (18), and check valve (19). 5. Pull out spool from valve body as follows. 1) Remove case (20), then remove springs (21) and (22), and retainer (23). 2) Pull out spool (24) from valve body. 6. Pull out spool from valve body as follows. 1) Remove case (25), then remove springs (26) and (27), and retainer (23). 2) Pull out spools (28), (29), and (30) from valve body. 7. Remove orifice (31) and jet sensor relief valve (32). 8. Remove suction-safety valves (33) and (34). 9. Remove suction valve (35). 10. Remove 2-stage safety valve (36). 11. Remove main relief valve (37).
PC750, 800-7
30-85 (2)
DISASSEMBLY AND ASSEMBLY
30-86 (2)
CONTROL VALVE ASSEMBLY (WORK EQUIPMENT)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
ASSEMBLY a The operation described below is for the right 4spool control valve (with straight-travel valve), but the procedure is basically the same for the left 5-spool control valve also. a Coat the sliding surface with engine oil when assembling. 1. Fit O-ring and install main relief valve (37). 3 Main relief valve: 320.95 ± 46.55 Nm {32.75 ± 4.75 kgm} 2. Fit O-ring and install 2-stage safety valve (36). 3 2-stage safety valve : 225.4 ± 9.8 Nm {23 ± 1 kgm}
CONTROL VALVE ASSEMBLY (WORK EQUIPMENT)
10. Assemble straight-travel valve as follows. 1) Fit O-ring and backup ring (38), then install sleeve (14), and tighten nut (13). 2) Assemble check valve (12) and spring (11), then fit O-ring and backup ring (39) and install plug (10). 3) Assemble spring (9), spool (8), and piston (7) to valve body, then fit O-ring and install sleeve (6). 4) Fit backup ring (5) and install plug (4). 5) Install cover (3). 11. Fit O-ring, then fit straight-travel valve assembly (2), and tighten mounting bolts (1).
3. Fit O-ring and install suction valve (35). 3 Suction valve: 225.4 ± 9.8 Nm {23 ± 1 kgm} 4. Fit O-ring and install suction-safety valves (34) and (33). 3 Suction-safety valve: 225.4 ± 9.8 Nm {23 ± 1 kgm} 5. Fit O-ring and install jet sensor relief valve (32) and orifice (31). 3 Jet sensor relief valve : 186.2 ± 9.8 Nm {19 ± 1 kgm} 3 Orifice: 151.9 ± 24.5 Nm {15.5 ± 2.5 kgm} 6. Install spool to valve body as follows. 1) Assemble spools (30), (29), and (28) to valve body. 2) Assemble retainer (23), and springs (26) and (27), then fit O-ring and install case (25). 7. Install spool to valve body as follows. 1) Assemble spool (24) to valve body. 2) Assemble retainer (23), and springs (22) and (21), then fit O-ring and install case (20). 8. Assemble check valve (19), spring (18), and seat (17) to valve body. 9. Install check valve (16) and spring (15).
PC750, 800-7
30-87 (2)
DISASSEMBLY AND ASSEMBLY
SOLENOID VALVE
REMOVAL AND INSTALLATION OF SOLENOID VALVE ASSEMBLY REMOVAL k
Lower the work equipment to touch the ground completely and stop the engine. After that, slowly loosen the cap of the hydraulic oil tank to release the inside pressure of the hydraulic oil tank. k Separate the (–) terminal of the battery. a Put the counter mark before separating the PPC circuit hose. a Put the plug to the separated tube and hose. 1. Boom damping valve 1) Remove the tool box (1) positioned in front of the hydraulic oil tank.
2. Straight traveling valve, 2-stage boom head safety valve, travel speed change-over valve, main 2-stage relief valve and CO canceling valve 1) Make the access from the hole (1) of the lower surface of the revolving frame. 2) Remove the clips (5) and (6). 3) Separate the wiring connectors (2) (V02, 03, 05, 06 and 07). 4) Remove the bolt (3) and remove the coil (4). a V2 : Main 2-stage relief valve V3 : Straight traveling valve V5 : 2-stage boom head safety valve V6 : Travel speed change-over valve V7 : CO canceling valve 3. Swing holding brake valve 1) Make the access from the hole of the lower surface of the revolving frame. 2) Remove the clip (5). 3) Separate the wiring connector (2) (V04). 4) Remove the bolt (3) and remove the coil (4). a V4 : Swing holding brake valve
2) Separate the wiring connectors (2) (V9 and V10). 3) Remove the nut (3) and remove the coil (4). a V9 and V10: Boom damping solenoid valve
30-88 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
4. Swing priority change-over valve 1) Make the access from the hole of the lower surface of the revolving frame. 2) Remove the clip (5). 3) Separate the wiring connector (2) (V04). 4) Remove the bolt (3) and remove the coil (4). a V1 : Swing priority change-over valve
PC750, 800-7
SOLENOID VALVE
INSTALLATION •
Installation shall be made in the reversed procedure of the removal procedure. a Pay attention so that dust, etc. shall not adhere to the coil insertion section.
30-89 (2)
DISASSEMBLY AND ASSEMBLY
BOOM DAMPING VALVE
REMOVAL AND INSTALLATION OF BOOM DAMPING VALVE ASSEMBLY REMOVAL
INSTALLATION
Lower the work equipment to touch the ground completely and stop the engine. After that, slowly loosen the cap of the hydraulic oil tank to release the inside pressure of the hydraulic oil tank. k Separate the (–) terminal of the battery. a Release the remaining pressure from the PPC circuit. a Put the plug to the separated hose.
•
Installation shall be made in the reversed procedure of the removal procedure.
•
Air Bleeding Carry out air bleeding of the PPC piping circuit referring to the section "Air bleeding of each section" in the "Testing and adjusting".
k
1. Remove the tool box (1) positioned in front of the hydraulic oil tank.
2. Separate the solenoid wiring connectors (2) (V9 and V10). 3. Separate the 4 pcs. of the hoses (3) and (4) between the solenoid valve and the damping valve. a Separate the hose between the damping valve and the PPC valve, RH and separate the hose between the damping valve and the relay joint. 4. Remove the mounting bolt to remove the damping valve assembly (5).
30-90 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
SWING MOTOR
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY REMOVAL k
Lower the work equipment to touch the ground completely and stop the engine.
k
1) Referring to the section "Releasing the remaining pressure from the hydraulic circuit on PPC valve installed machines" in the "Testing and adjusting", release the remaining pressure from the hydraulic circuit. 2) Slowly loosen the cap of the hydraulic oil tank to release the inside pressure of the hydraulic oil tank. a Center side of the machine body 1. Separate the hoses (1) and (2) from the control valve and separate the hoses (3) and (4) to the swing motor positioned in the front section of the machine body.
a Front side of the machine body 1. Separate the hoses (10) and (11) from the swing motor positioned in the central section of the machine body. 2. Separate the swing holding brake hose (12) and the drain hose (13).
2. Separate the swing holding brake hose (5) and the drain hose (6). 3. Remove the U-bolt (7) of the oil gauge tube, remove the bolt (8) and remove the bracket (9).
3. Separate the swivel joint section hose (14).
4. Remove the bolt (15) and remove the bracket (16). 5. Loosen the 4 pcs. of the bolt (17) and remove the swing motor assembly (18)/(19). 4
PC750, 800-7
Swing motor assembly: 57 kg x 2
30-91 (2)
DISASSEMBLY AND ASSEMBLY
SWING MOTOR
INSTALLATION •
Installation shall be made in the reversed procedure of the removal procedure. 3 Swing motor assembly mounting bolt: 926.7 ± 102.9 Nm {94.5 ± 10.5 kgm}
•
Filling the oil a Fill the oil to the stipulated level from the oil filler port and circulate the oil inside the piping. After that, re-check the oil level. a Fill the quantity of the oil which leaked when the motor assembly was removed.
30-92 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT REMOVAL k
Lower the work equipment to touch the ground completely and stop the engine. After that, slowly loosen the cap of the hydraulic oil tank to release the inside pressure of the hydraulic oil tank.
1. Separate the lower section hoses (1), (2), (3) and (4) of the swivel joint.
INSTALLATION •
a Regarding the port positioned in the lower section of the swivel joint, install the swivel joint so that the "A port" may be directed to the front-RH side.
2. Separate the upper section hoses (5), (6), (7) and (8) of the swivel joint.
3. Pull out the pin (9) and shift the link (10) to the direction of the frame side. a Separate the hose (12) between the swing motor. 4. Temporarily hang the swivel joint assembly. a Use the hole of the split flange bolt.
Installation shall be made in the reversed procedure of the removal procedure.
•
Filling the oil a Fill the oil to the stipulated level from the oil filler port and circulate the oil inside the piping. After that, re-check the oil level. a Fill the quantity of the oil which leaked when the swivel joint assembly was removed.
5. Removing the lower side mounting bolt, hang the swivel joint assembly (11) to remove it. 4
Center swivel joint assembly: 70 kg
PC750, 800-7
30-93 (2)
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
Part No.
790-101-2501
Part Name
Push-puller
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
t 1
• 790-101-2510 • Block
t 1
• 790-101-2520 • Screw
t 1
• 791-112-1180 • Nut
t 1
T • 790-101-2540 • Washer
t 1
• 790-101-2630 • Leg
t 2
• 790-101-2570 • Plate
t 2
• 790-101-2560 • Nut
t 2
• 790-101-2660 • Adapter
t 2
DISASSEMBLY
1
2 3
4
7
6
5
1. Remove cover (1). CEP00381
2. Remove snap ring (2). 3. Using push-puller T, pull out swivel rotor (4) and ring (3) from swivel shaft (5). 4. Remove O-ring (6) and slipper seal (7) from swivel rotor.
30-94 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT
ASSEMBLY 1. Assemble slipper seal (7) and O-ring (6) to swivel rotor. 2. Set swivel shaft (5) on block, then using pushpuller T, tap swivel rotor (4) with a plastic hammer to install. 2 Contact surface of rotor, shaft: Grease (G2-LI) a When installing the rotor, be extremely careful not to damage the slipper seal and O-ring.
3. Install ring (3) and secure with snap ring (2). 4. Fit O-ring and install cover (1). 3 Mounting bolt: 66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
PC750, 800-7
30-95 (2)
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY
K
Part No.
Part Name
796-660-1560 Guide-bolt
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
3. Remove 2 mounting bolts from travel motor and set tool K in position. 4. Remove remaining mounting bolts, then pull out travel motor assembly (6) and sling. 5. Lift off travel motor assembly (6). 4
t 2 N
Travel motor assembly: 140 kg
REMOVAL k
Swing the work equipment 90°, then lower it completely to the ground. k Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Lift off cover (1). 4
Cover: 120 kg
INSTALLATION •
Carry out installation in the reverse order to removal.
a After connecting the hoses, add engine oil through plug (7) until it reaches the bottom of the port. 2. Disconnect hoses (2), (3), (4), and (5). a Fit plugs into the hoses.
3 Mounting bolt: 384.7 ± 41.65 Nm {39.25 ± 4.25 kgm} a There is no air bleed plug, so add oil through the brake valve side plug when installing. a Run the engine to circulate the oil through the system. Then add engine oil to the hydraulic tank to the specified level.
30-96 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT PPC VALVE
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY DISASSEMBLY 1. Remove nut (1), then remove disc (2) and boot (3). 2. Remove bolt, then remove plate (5). a Do not remove joint (4) unless it is to be replaced. 3. Remove seal (6) and collar (7). 4. Pull out piston (8), and remove retainer (9), springs (10) and (11), and shim (12). a Spring (10) consists of two springs each of two types with different installed loads, so check the mounting position (hydraulic port) and mark with tags to prevent mistakes when installing. 5. Pull out valve (13) from body (14).
PC750, 800-7
30-97 (2)
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT PPC VALVE
ASSEMBLY 1. Assemble valve (13) to body (14). 2. Assemble shim (12) and spring (11) to valve (13). a When assembling spring (11), set the end with the small coil diameter (inside diameter) at shim (12) end. 3. Assemble spring (10), retainer (9), and piston (8). a The number of loops in the coil for spring (10) is different for each of the hydraulic ports below, so be careful when installing. Positon of port
Free length of spring (mm)
P1, P2
38.71
P3, P4
42.48
a The position of each port is marked at the bottom of the valve body. 2 Piston: Grease (G2-LI) a When assembling piston (8), coat the outside circumference of the piston and the inside circumference of the hole in the body with grease. 4. Fit O-ring to collar (7) and assemble to body (14), then install seal (6).
6. Install joint (4). 2 Joint sliding surface: Grease (G2-LI) 2 Female thread in body: Thread tightener (LT-2) a Coat two places on the female thread with one drop of Loctite each as shown in the diagram below. 3 Joint: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm} a Keep strictly to the tightening torque for the joint.
CEP00425
7. Assemble boot (3) and disc (2), and tighten with nut (1). 3 Nut: 112.7 ± 14.7 Nm {11.5 ± 1.5 kgm} a After assembling the disc, adjust the height of the disc. For details, see TESTING AND ADJUSTING, Adjusting PPC valve.
5. Install plate (5). 3 Mounting bolt: 13.23 ± 1.47 Nm {1.35 ± 0.15 kgm}
30-98 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
TRAVEL PPC VALVE
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY DISASSEMBLY 1. Remove screw (1), then remove lever (2). 2. Remove mounting bolt (3), then remove case and shaft assembly (4). 3. Remove 4 mounting bolts (5), then remove plate and damper assembly (6). a Check the thickness and mounting position of washer (7). 4. Remove mounting bolt (8), then remove damper assembly (9) from plate (10). 5. Remove seal (11) and collar (12). 6. Pull out piston (13), and remove retainer (14), springs (15) and (16), and shim (17). a Check the number and thickness of shims (17) for each mounting position, and keep in a safe place. 7. Pull out valve (18) from body (19). 8. Disassembly of case and shaft assembly 1) Knock pin (20) in shaft and remove shaft (21). 2) Remove lever (22). 3) Pull out pin (20) from shaft (21).
PC750, 800-7
30-99 (2)
DISASSEMBLY AND ASSEMBLY
TRAVEL PPC VALVE
ASSEMBLY 1. Assemble valve (18) to body (19). 2. Assemble shim (17) and spring (16) to valve (18). a Assemble the same number and thickness of shim (17) in the same position as was removed during disassembly. Standard shim thickness : 0.3 mm a Spring (16) is not symmetrical at the top and bottom, so assemble with the small coil diameter (inside diameter) at the shim end. 3. Assemble spring (15), retainer (14), and piston (13). 2 Outside circumference of piston, body hole: Grease (G2- LI) 4. Fit O-ring to collar (12) and assemble to body (19), then install seal (11). 5. Install damper assembly (9) to plate (10), and tighten mounting bolt (8). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 4.41 ± 0.49 Nm {0.45 ± 0.05 kgm} 6. Install plate and damper assembly (6), and tighten mounting bolt (8). a Temporarily assemble standard washer (1.6 mm) for washer (7). After completing the assembly, measure the difference in the angle when the left and right levers are operated fully. If the angle is greater than 0.7°, change the thickness of washer (7) to make the difference less than 0.7°. • Washer thickness 1.0, 1.3, 1.6 mm a If the washer is made 0.3 mm thinner, the angle at the full stroke is increased by 0.39°. 3 Mounting bolt: 30.87 ± 3.43 Nm {3.15 ± 0.35 kgm} 7. Install case and shaft assembly (4), and tighten mounting bolt (3). 2 Rocking portion of shaft, connection of lever and piston: Grease (G2-LI) 3 Mounting bolt: 27.95 ± 3.43 Nm {2.85 ± 0.35 kgm} 8. Install lever (2), and tighten screw (1). 2 Rocking portion of lever pin and plate: Grease (G2-LI) 3 Screw: 8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}
30-100 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
BUCKET CYLINDER
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY BACK HOE REMOVAL k
Retract the arm and bucket cylinder piston rods, lower the work equipment completely to the ground, then set the safety lock lever to the LOCK position.
1. Set block and block
7
6
5
between bucket cylinder and arm, between link and arm.
2. Remove 3 pin lock bolts (1) and cover (2), then using forcing screws, pull out. a Check the number and thickness of the shims, and keep in a safe place.
CEP00077
INSTALLATION •
3. Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. k Stop the engine and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit.
Carry out installation in the reverse order to removal. 2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Adjust with shims (4) so that the clearance a between link (7) and cover (2) is less than 1 mm. • Shim thickness: 0.8 mm (STD) 1.0 mm (SE)
4. Disconnect 2 hoses (3). a Fit plugs in the hoses to prevent dust or dirt from entering. 5. Sling bucket cylinder assembly (5), then remove plate (6) and pull out pin (7). a There are shims installed, so check the number, thickness, and position, and keep in a safe place. 6. Remove bucket cylinder assembly (5). 4
Bucket cylinder assembly: 550 kg (PC750) 980 kg (PC750SE, PC800SE) 600 kg (PC800)
PC750, 800-7
30-101 (2)
DISASSEMBLY AND ASSEMBLY
BUCKET CYLINDER
2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Adjust with shims (9) so that the clearance b between bracket (8) and the end face of of bottom of cylinder (5) is less than 1 mm. • Shim thickness: 0.8 mm (STD) 1.0 mm (SE)
•
Bleeding air a Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.
•
Refilling with oil (hydraulic tank) a Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-102 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
BUCKET CYLINDER
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY LOADING SHOVEL REMOVAL k
Extend the arm cylinder fully, set the bottom of the bucket horizontal, lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. k Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. a Fit plugs in the hoses after disconnecting them, to prevent dirt or dust from entering. 1. Sling bucket cylinder assembly, and remove 3 mounting bolts, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), remove pin (1). k When the pin is removed, links (2) and (3) will drop, so sling the links before removing the pin. 4 Pin: 37 kg
3. Disconnect grease tube (4). 4. Disconnect hose (5).
5. Sling piston rod end and bottom end, and remove plate, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (6). a Pull out the pin to a position where the cylinder bottom can be disconnected.
4
2. Start engine and retract piston rod fully. k Tie the rod with wire to prevent it from coming out. k After stopping the engine, release the pressure inside the piping. For details, see TESTING AND ADJUSTING, Releasing pressure in PPC circuit.
PC750, 800-7
Pin: 35 kg
6. Raise bucket cylinder assembly (7) carefully and remove. 4
Bucket cylinder assembly: 555 kg
30-103 (2)
DISASSEMBLY AND ASSEMBLY
BUCKET CYLINDER
INSTALLATION •
Carry out installation in the reverse order to removal. k
k
When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
When aligning the mounting position of the pin, do not insert your fingers in the pin hole. a Adjust with shims so that the clearance at the cylinder bottom end is less than 1 mm.
a Bleed the air from the work equipment circuit. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. •
Refilling with oil a Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
30-104 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
ARM CYLINDER
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY BACK HOE
Part No.
V 2
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
791-650-1610 Bracket
t 1
790-445-4130 Screw
t 1
791-112-1180 Nut
t 1
01643-32780 Washer
t 1
790-101-2102
Puller (294 kN {30 ton})
790-101-1102 Pump
t 1 t 1
REMOVAL k
Extend the arm cylinder piston rod to a point approx. 200 mm before the end of the IN stroke, lower the work equipment completely to the ground, then set the safety lock lever to the LOCK position.
1. Set block
a If the pin does not come out, use tool V2 and remove the pin from the head end.
between arm cylinder and boom.
2. Disconnect grease hose (1). 3. Remove plate (2), and pull out head pin (3).
4
4. Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. k Stop the engine and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit. 5. Disconnect hose (4) and grease hose (5). a Fit plugs in the hoses to prevent dust or dirt from entering. 6. Sling arm cylinder assembly (6), then remove plate (7) and pull out bottom pin (8). a If the pin does not come out, use tool V2 and remove the pin from the bottom end. a There are shims installed, so check the number, thickness, and position, and keep in a safe place. 7. Remove arm cylinder assembly (6).
4 Arm cylinder assembly: 915 kg (PC750STD) 540 kg x 2 (PC750SE, PC800, PC800SE)
1 2 3
8
7
5
CEP00522
6 CEP00523
PC750, 800-7
30-105 (2)
DISASSEMBLY AND ASSEMBLY
ARM CYLINDER
•
Bleeding air a Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.
•
Refilling with oil (hydraulic tank) a Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
INSTALLATION •
Carry out installation in the reverse order to removal. 2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. 2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Adjust with shims (10) so that the clearance a between bracket (9) and the bottom end face of cylinder (6) is less than 1 mm. • Shim thickness: 0.8 mm
30-106 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
ARM CYLINDER
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY LOADING SHOVEL REMOVAL k
Retract boom cylinder fully, and extend arm cylinder, then set the bottom of the bucket horizontal, lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. k Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. a Fit blind plugs in the hoses after disconnecting them, to prevent dirt or dust from entering. 1. Disconnect grease tube (1) at piston rod end.
3. Start engine and retract piston rod fully. k Tie the rod with wire to prevent it from coming out. k After stopping the engine, release the pressure inside the piping. For details, see TESTING AND ADJUSTING, Releasing pressure in PPC circuit. 4. Disconnect hose (3). 5. Sling piston rod end and bottom end, and remove plate, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (4). a Pull out the pin to a position where the cylinder bottom can be disconnected. 4
Pin: 56 kg
2. Sling arm cylinder assembly, and remove plate, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (2). a Pull out the pin to a position where the piston rod can be disconnected. 4
Pin: 56 kg
PC750, 800-7
6. Lift off arm cylinder assembly (5) carefully. 4
Arm cylinder assembly: 845 kg
30-107 (2)
DISASSEMBLY AND ASSEMBLY
ARM CYLINDER
INSTALLATION •
Carry out installation in the reverse order to removal.
k
When aligning the mounting position of the pin, do not insert your fingers in the pin hole. k When aligning the mounting position of the pin, do not insert your fingers in the pin hole. a Adjust with shims so that the clearance at the cylinder bottom end is less than 1 mm. a Bleed the air from the work equipment circuit. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. •
Refilling with oil a Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
30-108 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
BOOM CYLINDER
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY BACK HOE
3. Sling boom cylinder assembly.
Part No.
Part Name
790-445-4100 Remover 1 790-101-4200
V
Puller (294 kN {30 ton})
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
t 1 t 1
790-101-1102 Pump
t 1
790-445-4120 Sleeve
t 1
791-520-4140 Screw
t 1
796-775-1110 Adapter
t 1
3 791-112-1180 Nut 01643-32780 Washer 790-101-2102
Puller (294 kN {30 ton})
790-101-1102 Sleeve
4. Using tool V3, pull out head pin (3), then disconnect piston rod from boom.
t 1 t 1 t 1 t 1
5. Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. k Stop the engine and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit. 6. Lower boom cylinder assembly on stand, then disconnect hose (4).
REMOVAL k
Retract the arm and bucket cylinder piston rods fully, lower the work equipment completely to the ground, then put the safety lock lever in the LOCK position. a Fit plugs in the hoses to prevent dust or dirt from entering.
7. Disconnect grease hose (5). 8. Sling boom cylinder assembly and remove plate (6).
1. Disconnect grease tube (1). 2. Remove plate (2).
PC750, 800-7
30-109 (2)
DISASSEMBLY AND ASSEMBLY
9. Using tool V1, pull out bottom pin (7). 10. Remove boom cylinder assembly. 4
BOOM CYLINDER
INSTALLATION •
Boom cylinder assembly: 840 kg x 2
Carry out installation in the reverse order to removal. 2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. 2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Adjust with shims (10) so that the clearance a between bracket (9) and the bottom end face of boom cylinder (8) is less than 1 mm. • Shim thickness: 1.0, 1.5 mm
30-110 (2)
•
Bleeding air a Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.
•
Refilling with oil (hydraulic tank) a Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
BOOM CYLINDER
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY LOADING SHOVEL REMOVAL k
Extend the arm and bucket fully, lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. k Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. a Fit plugs in the hoses after disconnecting them, to prevent dirt or dust from entering.
6. Sling boom cylinder assembly, and remove plate, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out foot pin (5).
1. Disconnect grease hose (1). 2. Remove plate (2). 3. Sling boom cylinder assembly, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (3), and disconnect piston rod from boom.
7. Remove boom cylinder assembly (6). 4
Boom cylinder assembly: 720 kg
4. Start engine and retract piston rod fully. k Tie the rod with wire to prevent it from coming out. k After stopping the engine, release the pressure inside the piping. For details, see TESTING AND ADJUSTING, Releasing pressure in PPC circuit. 5. Lower boom cylinder assembly onto stand, then disconnect hose (4).
PC750, 800-7
30-111 (2)
DISASSEMBLY AND ASSEMBLY
BOOM CYLINDER
INSTALLATION •
Carry out installation in the reverse order to removal. k
k
When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
When aligning the mounting position of the pin, do not insert your fingers in the pin hole. a Adjust with shims so that the clearance at the cylinder bottom end is less than 1 mm.
a Bleed the air from the work equipment circuit. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. •
Refilling with oil a Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
30-112 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
BOTTOM DUMP CYLINDER
REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY LOADING SHOVEL REMOVAL k
Set the bottom of the bucket horizontal, and retract the rod to a position where the rod connecting pin of the bottom dump cylinder can be removed. Then fit a block under the bucket, lower the work equipment completely to the ground and stop the engine. a Fit plugs in the hoses after disconnecting them, to prevent dirt or dust from entering.
5. Remove 3 mounting bolts, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (4). 4
Pin: 35 kg
6. Lift off bottom dump cylinder assembly (5). 4
Bottom dump cylinder assembly: 140 kg
1. Remove cover (1). 2. Sling bottom dump cylinder assembly, and remove lock plate, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (2).
INSTALLATION •
Carry out installation in the reverse order to removal. k
3. Start engine and retract piston rod fully. k After stopping the engine, release the pressure inside the piping. For details, see TESTING AND ADJUSTING, Releasing pressure in PPC circuit.
k
4. Remove hose (3).
When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
a Bleed the air from the work equipment circuit. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. •
PC750, 800-7
Refilling with oil a Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
30-113 (2)
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY a Place a container under the cylinder to catch the oil.
Part Name
Sketch
Part No.
Necessity Q’ty New/Remodel
Symbol
SPECIAL TOOLS
Cylinder repair t 2 stand
1
790-502-1003
2
790-720-1000 Expander
t 1 N Q
796-720-1690 Ring
t 1
796-720-1720 Ring
t 1
07281-02169 Clamp
t 1
796-720-1690 Ring
t 1
07281-01919 Clamp
t 1
07281-02429 Clamp
t 1
790-201-1702 Push took kit
t 1
3
U 4
• 790-201-1881 • Push tool
t 1
• 790-201-1871 • Push tool
t 1
• 791-863-1110 • Push tool
t 1
• 790-101-5421 • Grip
t 1
• 01010-51240 • Blot
t 1
• 790-101-5021 • Grip
t 1
• 01010-50816 • Bolt
t 1
790-201-1500 Push tool kit
5
6
t 1
• 790-201-1690 • Plate
t 1
• 790-201-1680 • Plate
t 1
• 792-715-1400 • Push tool
t 1
• 790-101-5421 • Grip
t 1
• 01010-51240 • Bolt
t 1
• 790-101-5021 • Grip
t 1
• 01010-51240 • Blot
t 1
4) Disassemble piston rod assembly as follows. i) Set piston rod assembly (2) to tool U1.
ii)
Remove piston assembly stopper screw (3). • Applicable to: Boom and arm cylinder for standard and SE specifications. Bucket cylinder for standard specification. Screw size: M12 x pitch 1.75
DISASSEMBLY 1. Piston rod assembly 1) Remove piping from cylinder assembly. 2) Remove mounting bolts, and disconnect head assembly (1). 3) Pull out piston rod assembly (2).
30-114 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
a If screw (3) has been caulked strongly and cannot be removed, screw it in fully, then fit a tap to the thread and pull it out.
iii) Using tool U6, remove piston assembly (4). • When not using tool U6, use the drill holes ( 10: 4 places) and loosen the piston assembly. • Applicable to: Boom and arm cylinder for standard and SE specifications. Bucket cylinder for standard specification.
HYDRAULIC CYLINDER
iv) Remove 6 screws (21), then remove spacer (22), and remove piston ass’y (4) and O-ring, back-up ring (23). • Applicable to bucket cylinder for SE specification.
v) Remove plunger (5). vi) Remove collar (6). vii) Remove head assembly (7).
viii) Remove cap (8), and pull out 11 balls (9), then remove cushion plunger (10). • Applicable to arm cylinder.
PC750, 800-7
30-115 (2)
DISASSEMBLY AND ASSEMBLY
2. Disassembly of piston assembly 1) Remove ring (11). 2) Remove wear ring (12). a Two pieces are installed to each of the bucket cylinder and boom cylinder, and four pieces to the arm cylinder. 3) Remove piston ring (13). 4) Remove O-ring and backup ring (14).
HYDRAULIC CYLINDER
ASSEMBLY a Be careful not to damage the packings, dust seals, and O-rings. a Do not try to force the backup ring into position. Warm it in warm water (50 – 60°C) before fitting it. 1. Assembly of cylinder head assembly 1) Using tool U4, press fit bushing (20). 2) Assemble buffer ring (19). 3) Assemble rod packing (18). 4) Using tool U5, install dust seal (17), and secure with snap ring (16). 5) Install backup ring and O-ring (15).
3. Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (15). 2) Remove snap ring (16), then remove dust seal (17). 3) Remove rod packing (18). 4) Remove buffer ring (19). 5) Remove bushing (20).
30-116 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
2. Assembly of piston assembly 1) Using tool U2, expand piston ring (13). a Set the piston ring on tool U2, and turn the handle 8 – 10 times to expand the ring. 2) Set tool U3 in position, and compress piston ring (13).
3) Install backup ring and O-ring (14). 4) Assemble wear ring (12). 5) Assemble ring (11). a Be careful not to open the end gap of the ring too wide. 2 Ring groove : Grease (G2-LI)
HYDRAULIC CYLINDER
2) Assemble head assembly (7). 3) Fit O-ring and backup ring to collar (6), then assemble. 4) Assemble plunger (5). a After tightening the piston, check that the plunger has a little play.
5) Set cushion plunger (10) to piston rod, then assemble 11 balls (9), and secure with cap (8). • Applicable to arm cylinder a After installing, check that the cushion plunger end has a little play.
3. Piston rod assembly 1) Set piston rod assembly (2) to tool U1.
PC750, 800-7
30-117 (2)
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
a. Screw in until piston assembly (4) contacts end face of rod, then use tool U6 to tighten. 3 Piston assembly (4): 294 ± 29.4 Nm {30 ± 3.0 kgm} a After tightening the piston, check that there is play in plunger (5).
6) Assemble piston assembly (4) as follows. i) When using rod and piston assembly (2) again a Wash thoroughly and remove all metal particles and dirt. a. Screw in piston assembly (4), then use tool U6 to tighten piston assembly so that position of screw thread hole matches. a Remove all burrs and flashes with a file.
b. Machine one hole used to install screw (3). a Apply the drill to the V-groove between piston (4) and threaded part of rod (2), and make a hole horizontally. a For the cylinder with bottom cushion (arm cylinder), avoid the cushion plug position when machining. • Screw machining dimension (mm)
b. Tighten screw (3). 3 Screw (3): 58.9 – 73.6 Nm {6 – 7.5 kgm} c. Caulk thread at 2 places with punch.
Cylinder
ii)
30-118 (2)
Drill Bottom Tap Tap used diameter hole depth depth
Bucket Boom
10.3
36
12 x 1.75
29
Arm
10.3
43
12 x 1.75
36
When using a new part for either or both of rod or piston assembly (2) a For the rod with bottom cushion, mark the cushion plug position on the end face of the rod. • Applicable to arm cylinder
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
c.
After machining, wash thoroughly to remove all metal particles and dust. d. Tighten screw (3). 2 Threaded part: Thread tightener (Locktite No. 262 or equivalent) 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm} e. Caulk thread at 4 places with punch.
7) Install O-ring, back-up ring (23), piston ass’y (4) and spacer (22), then retighten them with screw (21). 2 Threaded part: Thread tightener (Locketite No. 262 or equivalent) • Applicable to bucket cylinder of SE specification
HYDRAULIC CYLINDER
8) Assemble piston rod assembly (2). 2 Seal portion: Grease (G2-LI) a Set the end gap of the ring at the horizontal (side) position, align the axial center of shaft and cylinder tube, then insert. a After inserting, check that the ring is not broken and has not come out, then push in fully.
9) Tighten head assembly (1) with mounting bolts. 3 Mounting bolt : Cylinder
Tightening torque
STD Bucket, SE Arm
892 ± 137 Nm {91.0 ± 14 kgm}
STD Arm, Boom
1,270 ± 200 Nm {130 ± 20 kgm}
SE Bucket
1,670 ± 250 Nm {170 ± 25 kgm}
10) Install piping.
PC750, 800-7
30-119 (2)
DISASSEMBLY AND ASSEMBLY
BUCKET
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY BACK HOE REMOVAL k
Set the back of the bucket facing down, lower the work equipment completely to the ground, then set the safety lock lever to the LOCK position.
7. Start engine and raise work equipment, disconnect arm from bucket, then remove bucket assembly. 4
1. Remove 3 pin lock bolts (1), then remove stopper (2).
Bucket assembly: 2,960 kg (PC750STD) 3,560 kg (PC800STD) 3,435 kg (PC750SE) 3,870 kg (PC800SE)
INSTALLATION •
2. Using forcing screws, remove connecting pin of link and bucket. 3. Start engine, and retract piston rod, then tie link to arm with wire to prevent piston rod from coming out. k
Stop the engine and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit.
4. Remove 3 pin lock bolts (3), then remove stopper (4). 5. Remove cover (5), then remove shims (6). a Check the number and thickness of the shims, and keep in a safe place. 6. Using forcing screws, remove arm connecting pin (7).
30-120 (2)
Carry out installation in the reverse order to removal. 2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. 2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Insert the O-ring at the end face of the bucket boss securely. a Adjusting of bucket clearance 1) Measure clearance a between arm (8) and bushing (9). a It is easier to measure if the bucket is moved to one side so that all the play is in one place. 2) Select shims so that clearance a is 0.5 to 1.0 mm. • Shim thickness b: 0.5, 1.0 mm 3) Install selected shims and install cover (5).
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
BUCKET
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY LOADING SHOVEL REMOVAL k
Set the bottom of the bucket horizontal, lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. k Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. a Fit plugs in the hoses after disconnecting them, to prevent dirt or dust from entering.
3. Sling bucket assembly, and remove 3 mounting bolts, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (4). a Remove the pin on the other side in the same way. 4
Pin: 52 kg
1. Disconnect bottom dump cylinder hose (1). 2. Sling bucket cylinder assembly, and remove 3 mounting bolts, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (2). a Remove the pin on the other side in the same way. k When the pin is removed, link (3) will drop, so sling the links before removing the pin. 4
4
4. Lift off bucket assembly (5). 4
Pin: 37 kg
Bucket assembly: 5,700 kg
Link: 440 kg
INSTALLATION •
Carry out installation in the reverse order to removal.
k
When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
a Bleed the air from the work equipment circuit. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. After completion of the air bleeding operation, add engine oil to the hydraulic tank to the specified level.
PC750, 800-7
30-121 (2)
DISASSEMBLY AND ASSEMBLY
ARM
REMOVAL AND INSTALLATION OF ARM ASSEMBLY BACK HOE
Part No.
2
791-650-1610 Bracket
t 1
790-445-4130 Screw
t 1
791-112-1180 Nut
t 1
01643-32780 Washer
t 1
790-101-2102
V
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
Puller (294 kN {30 ton})
t 1
790-101-1102 Pump
t 1
790-445-4120 Sleeve
t 1
791-520-4140 Screw
t 1
796-775-1110 Adapter
t 1
3 791-112-1180 Nut 01643-32780 Washer 790-101-2102
Puller (294 kN {30 ton})
790-101-1102 Sleeve
3
2
6
5
4
1
CEP00525
a If the pin does not come out, use tool V2 and remove the pin from the head end.
t 1 t 1 t 1 t 1
REMOVAL 1. Remove bucket assembly. F o r d e t a i l , s e e R E M O VA L O F B U C K E T ASSEMBLY. 2. Secure link to arm with wire. k Extend the arm cylinder piston rod to a point approx. 200 mm before the end of the IN stroke, then lower the arm on to block and stand , and set the safety lock lever to the LOCK position. Then, stop the engine.
6. Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. k Stop the engine and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit. 7. Disconnect 2 bucket cylinder hoses (4).
3. Set block between arm cylinder and boom. 4. Disconnect grease hose (1). 5. Remove plate (2), and pull out head pin (3) of arm cylinder.
30-122 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
ARM
8. Remove plate (5), then using tool V3, pull out boom top pin (6). a There are shims installed, so check the number, thickness, and position, and keep in a safe place.
INSTALLATION •
2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. 2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Adjust with shims so that the clearance a between boom (8) and the bottom end face of arm (7) is less than 1 mm. • Shim thickness : 1.0 mm
9. Start engine, then raise boom and remove arm assembly (7). 4
Carry out installation in the reverse order to removal.
Arm assembly: 3,960 kg (PC750STD) 4,530 kg (PC800STD) 4,930 kg (PC750SE, PC800SE)
7
CEP00526
PC750, 800-7
•
Bleeding air a Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.
•
Refilling with oil (hydraulic tank) a Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-123 (2)
DISASSEMBLY AND ASSEMBLY
ARM
REMOVAL AND INSTALLATION OF ARM ASSEMBLY LOADING SHOVEL REMOVAL 1. Remove bucket assembly. F o r d e t a i l s , s e e R E M O VA L O F B U C K E T ASSEMBLY.
6. Remove 3 mounting bolts (5), then remove potentiometer (6) together with bracket (7).
2. Start engine, and set work equipment so that bucket cylinder is perpendicular. 3. Remove 3 mounting bolts, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (1). a Remove the pin on the other side in the same way, then secure the link to the arm with wire so that it cannot move. 7. Remove arm cylinder from arm. For details, see REMOVAL OF ARM CYLINDER ASSEMBLY. a Secure the arm cylinder assembly to the boom with lever block .
4. Disconnect left and right bottom dump cylinder hoses (2). 5. Remove cover (3), and disconnect wiring (4) of potentiometer. 8. Sling arm assembly, and remove 3 mounting bolts, then using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out pin (8). a Pull out the pin on the other side in the same way to a position where the arm can be disconnected from the boom. 4
30-124 (2)
Pin: 45 kg
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
9. Lift off arm assembly (9). 4
Arm assembly: 3,070 kg
ARM
INSTALLATION •
Carry out installation in the reverse order to removal.
k
When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
a Bleed the air from the work equipment circuit. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. After completion of the air bleeding operation, add engine oil to the hydraulic tank to the specified level.
PC750, 800-7
30-125 (2)
DISASSEMBLY AND ASSEMBLY
BOOM
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY BACK HOE
Part No.
5. Sling boom assembly (10).
Part Name
790-445-4100 Remover V 1 790-101-4200
Puller (294 kN {30 ton})
790-101-1102 Pump
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
t 1 t 1
10
t 1
CEP00299
REMOVAL 1. Remove bucket and arm assembly. For details, see REMOVAL OF BUCKET, ARM ASSEMBLY. k Lower the boom assembly completely to the ground, then set the safety lock lever to LOCK position. 2. Disconnect boom cylinder assembly from boom. For details, see REMOVAL OF BOOM CYLINDER ASSEMBLY.
6. Using tool V1, remove 2 boom foot pins (7), then remove boom assembly. a There are shims installed, so check the number, thickness, and position, and keep in a safe place. 4
Boom assembly: 8,360 kg (PC750 STD) 8,790 kg (PC800 STD) 7,970 kg (PC750SE, PC800SE)
3. Disconnect front lamp wiring. 4. Disconnect bucket cylinder hoses (1) and arm cylinder hoses (2).
30-126 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
BOOM
INSTALLATION •
Carry out installation in the reverse order to removal. 2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers in the hole. a Adjust with shims so that the clearance a between bracket (4) and the end face of the foot of boom (3) is less than 1 mm. • Shim thickness : 1.0, 1.5 mm
•
Bleeding air a Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.
•
Refilling with oil (hydraulic tank) a Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
PC750, 800-7
30-127 (2)
DISASSEMBLY AND ASSEMBLY
BOOM
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY LOADING SHOVEL REMOVAL 1. Remove arm assembly. For details, see REMOVAL OF ARM ASSEMBLY. 2. Sling bucket cylinder assembly (1), remove plate, then pull out pin (2), and remove bucket cylinder assembly. 4
4
5. Disconnect bottom dump cylinder hose (3), bucket cylinder hose (4), and arm cylinder hose (5). a When the hoses are disconnected, oil may spurt out, so loosen the hose flanges slowly before disconnecting.
Pin: 35 kg Bucket cylinder assembly: 555 kg
a Remove the bucket cylinder on the other side in the same way.
6. Disconnect head lamp wiring. 7. Remove cover (6), and disconnect wiring (7) of potentiometer and cable (8).
3. Sling boom, set stand port boom.
at tip of boom to sup-
8. Remove 3 mounting bolts (9), then remove potentiometer assembly (10) together with bracket (11).
4. Remove boom cylinder from boom. For details, see REMOVAL OF BOOM CYLINDER ASSEMBLY. a Remove the boom cylinder on the other side from the boom in the same way.
30-128 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
9. Using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out left and right boom foot pins (12), then lift off boom (13). a Check the number and thickness of the shims, and keep in a safe place. 4
Boom: 4,490 kg
BOOM
INSTALLATION •
Carry out installation in the reverse order to removal.
k
When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
a Bleed the air from the work equipment circuit. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. After completion of the air bleeding operation, add engine oil to the hydraulic tank to the specified level.
PC750, 800-7
30-129 (2)
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
REMOVAL AND INSTALLATION OF WORK EQUIPMENT BACK HOE
Part No.
4. Temporarily hang the work equipment assembly.
Part Name
790-445-4100 Remover V 1 790-101-4200
Puller (294 kN {30 ton})
790-101-1102 Pump
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
t 1 t 1 t 1
REMOVAL k
Contract the arm and bucket cylinder piston rods, lower the work equipment to touch the ground completely and set the safety lock lever to the lock position. a Referring to the section "Releasing the remaining pressure from the hydraulic circuit" in the "Testing and adjusting", release the remaining pressure from the hydraulic circuit.
5. Using the tool V1, remove the 2 pcs. of the boom foot pin (7). a Since the shim is being installed, confirm the number of sheets and the position.
1. Referring to the section "Removal of the boom cylinder assembly", separate the boom cylinder assembly from the boom. 2. Separate the head lamp wire. 3. Separate the bucket cylinder hose (1) and the arm cylinder hose (2).
6. Start the engine, back the machine slowly and lower the boom foot section to touch the ground using a crane. k When backing the machine, confirm that the boom foot section is completely separated from the machine body side before starting backing of the machine. 4
30-130 (2)
Work equipment assembly: 16,900 kg (PC750 STD) 18,300 kg (PC800 STD) 17,700 kg (PC750SE) 18,200 kg (PC800SE)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
INSTALLATION •
Installation shall be made in the reversed procedure of the removal procedure. 2 To the inner surface of the bushing when assembling the pin: Anti-friction material (LM-P) 2 Greasing after assembling the pin: Grease (LM-G) k When matching the position of the pin hole, never insert finger into the pin hole. a Make adjustment so that the clearance a between the end face of the foot of the boom (3) and the bracket (4) may become 1 mm or less, using the shim (5). • Shim thickness: 1.0 and 1.5 mm
•
Air Bleeding a Carry out air bleeding referring to the section "Air bleeding of each section" in the "Testing and adjusting".
•
Filling the oil (Hydraulic oil tank) a Fill the oil to the stipulated level from the oil filler port, start the engine to circulate the oil inside the piping and, after that, re-check the oil level.
PC750, 800-7
30-131 (2)
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
REMOVAL AND INSTALLATION OF WORK EQUIPMENT LOADING SHOVEL REMOVAL k
Retract the boom cylinder fully, extend the arm cylinder, set the bottom of the bucket horizontal, then lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. a Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit.
3. Disconnect head lamp wiring. 4. Remove potentiometer assembly. For details, see REMOVAL OF BOOM ASSEMBLY. 5. Set bottom of bucket horizontal, lower work equipment completely to ground, then sling boom assembly (4).
1. Disconnect boom cylinder from boom. For details, see REMOVAL OF BOOM CYLINDER ASSEMBLY. 2. Disconnect bottom dump cylinder hose (1), bucket cylinder hose (2), and arm cylinder hose (3). a When the hoses are disconnected, oil may spurt out, so loosen the hose flanges slowly before disconnecting. k To prevent oil from spurting out when the engine is started, fit blind plugs securely in the piping at the chassis end.
6. Using forcing screws (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out left and right boom foot pins (5), then disconnect work equipment assembly. a Check the number and thickness of the shims, and keep in a safe place.
7. Start engine, drive machine slowly in reverse, and operate crane to lower boom foot to ground. k Before driving the machine in reverse, check that the boom foot is completely separated from the machine body. 4 Work equipment assembly:16,200 kg
30-132 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
INSTALLATION •
Carry out installation in the reverse order to removal. k
When aligning the mounting position of the pin, do not insert your fingers in the pin hole. a Adjusting the lifting height of the boom assembly so that the boom foot is at the height of the mount on the chassis. a Bleed the air from the work equipment circuit. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. After completion of the air bleeding operation, add engine oil to the hydraulic tank to the specified level.
PC750, 800-7
30-133 (2)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY REMOVAL k
6. Remove left cover (7).
Disconnect the cable from the negative (–) terminal of the battery.
7. Disconnect center cover (8) and right cover (9).
1. Remove floor mat. 2. Remove operator’s seat (1). a Be careful not to damage the cover.
1
8. Remove the cover (10) and duct (11).
CEP00438
11
3. Remove knob (2). 4. Remove 4 bolts and 1 clip, then remove panels (3) and (4).
10 CEP00443
5. Disconnect hose (5) for window washer.
30-134 (2)
9. Separate the wiring intermediate connectors. a For intermediate section of the harness : CN-A11 : CN-A12 : CN-A13 : CN-A14 : CN-H10 : CN-H11 : CN-H12 : CN-H15 : CN-M72 a For speaker : CN-M13 : CN-M73 a For air conditioner : CN-AC1 : CN-AC2
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB
10. Remove the 4 pcs. of the mounting nuts and the 6 pcs. of the mounting bolts and hang the operator’s cab assembly to remove the operator’s cab. 4
Operator’s cab: 300 kg (PC750) 350 kg (PC800) • The mark shows the nut and the e mark shows the bolt. a Regarding the bolt, confirm the length in advance.
INSTALLATION •
Installation shall be made in the reversed procedure of the removal procedure. 3 Mounting nut: 276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
CEP00445
PC750, 800-7
30-135 (2)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)
a Among the panes of window glass on the 4 sides of the operator's cab, 4 panes (1) – (4) are stuck. In this section, the procedure for replacing the stuck glass is explained. When replacing front window glass (4), remove front window assembly (5). (It is impossible to replace only the front window glass while the front window assembly is installed to the operator's cab.) For the procedure for replacing the front window assembly, see REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY.
30-136 (2)
(1) : (2) : (3) : (4) : (5) :
Right side window glass Left side rear window glass Door lower window glass Front window glass Front window assembly (Front window glass + Front frame) (6) : Both-sided adhesive tape (16): Center trim seal
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
Y
1 793-498-1210
Lifter (Suction cup)
2 20Y-54-13180 Adapter
(The figure shows the operator's cab of a wheel loader.) Sketch
New/Remodel
Part name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
t 2 t 2
REMOVAL a Remove the window glass to be replaced according to the following procedure. 1. Using seal cutter [1], cut the adhesive between broken window glass (7) and operator's cab (metal sheet) (8).
a If the window glass is broken finely, it may be removed with knife [4] and a screwdriver. a Widening the cut with a screwdriver, cut the adhesive and both-sided adhesive tape with knife [4]. (The figure shows the operator's cab of a wheel loader.)
a If a seal cutter is not available, make holes on the adhesive and both-sided adhesive tape with a drill and pass a fine wire (piano wire, etc.) [2] through the holes. Grip the both ends of the wire with priors [3], etc. (or hold them by winding them onto something) and move the wire to the right and left to cut the adhesive and both-sided adhesive tape. Since the wire may be broken by the frictional heat, apply lubricant to it.
PC750, 800-7
2. Remove the window glass.
30-137 (2)
DISASSEMBLY AND ASSEMBLY
INSTALLATION 1. Using a knife and scraper [5], remove the remaining adhesive and both-sided adhesive tape from the metal sheets (glass sticking surfaces) of the operator's cab. a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surfaces. (If the painted surfaces are scratched, adhesion will be lowered.) (The figure shows the operator's cab of a wheel loader.)
OPERATOR’S CAB GLASS (STUCK GLASS)
3. Apply primer (10). a The using limit of primer (10) is 4 months after the date of manufacture. Do not use primer (10) after this limit. a Use the primer within 2 hours after unpacking it. a Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Discard the primer 24 hours after it is packed.) 1) Stir the primers for paint and glass sufficiently before using them. a If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a day before stirring it. (If the primer is unpacked just after taken out of the refrigerator, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.) 2) When reusing primer brush (11), wash it in white gasoline. a After washing the brush, check it again for dirt and foreign matter. a Prepare respective brushes for the paint primer glass primer.
2. Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and window glass (9) with white gasoline. a If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all black part on the back side of the window glass. a After cleaning the sticking surfaces, leave them for at least 5 minutes to dry. (The figure shows the operator's cab of a wheel loader.)
30-138 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
3) Evenly apply paint primer to the surfaces to stick both-sided adhesive tapes and the surfaces out of those surfaces on operator's cab (8) which will be coated with the adhesive. 2 Paint primer: SUNSTAR PAINT PRIMER 580 SUPER or equivalent a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
OPERATOR’S CAB GLASS (STUCK GLASS)
a In addition to the above parts, apply the primer to right side window glass (1) and door lower window glass (3). • Range to apply primer additionally for right side window glass (1): (b) • Range to apply primer additionally for door lower window glass (3): (c) a After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry.
a Parts to be coated with primer: Apply the primer all over dimension (a). • Dimension to apply primer (a): 25 mm
a Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline.
PC750, 800-7
30-139 (2)
DISASSEMBLY AND ASSEMBLY
4) Evenly apply glass primer to the sticking surfaces of window glass (9). 2 Glass primer: SUNSTAR GLASS PRIMER 580 SUPER or equivalent a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
a Parts to be coated with primer: Apply the primer to the sticking surfaces of window glass (9) and all over dimension (d) which will be on both-sided adhesive tape (6) and operator's cab (8). a Do not apply the primer to the boarder about 5 mm wide between the black part and transparent part of the glass. a After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. a Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline.
30-140 (2)
OPERATOR’S CAB GLASS (STUCK GLASS)
4. Stick both-sided adhesive tape (6) along the inside edge of the glass sticking section. a Do not remove the release tape of the bothsided adhesive tape on the glass sticking side before sticking the glass. a When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. a Take that the both-sided adhesive tape will not float at each corner of the window frame.
a When sticking both-sided adhesive tape (6) around a frame, do not lap its finishing end over the starting end but make clearance e of about 5 mm between them. 1) Stick both-sided adhesive tape (6) for right side window glass (1) as shown in the figure.
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
a Stick both-sided adhesive tape (6a) additionally for right side window glass (1). • Positions to stick additional both-sided adhesive tape for right side window glass: (f) : 50 mm (g) : 90 mm (h) : 250 mm
2) Stick both-sided adhesive tape (6) for left side rear window glass (2) as shown in the figure.
3) Stick both-sided adhesive tape (6) for door lower window glass (3) as shown in the figure.
PC750, 800-7
OPERATOR’S CAB GLASS (STUCK GLASS)
a Stick both-sided adhesive tape (6b) additionally for door lower window glass (3). a Positions to stick additional both-sided adhesive tape for door lower window glass: (j) : 110 mm (k) : 90 mm (m) : 200 mm
4) Stick both-sided adhesive tape (6) for front window glass (4) as shown in the figure.
a Stick both-sided adhesive tape (6c) of the lower side of the front window glass along the outside edge of the lower line, differently from other both-sided adhesive tapes (6). (If it is stuck along the inside, it will be seen through the transparent part of the glass.)
30-141 (2)
DISASSEMBLY AND ASSEMBLY
5. Position the new window glass. 1) Check the clearance between the window glass and the operator's cab on the right, left, upper, and lower sides, and then adjust it evenly. 2) Stick tapes [6] between window glass (9) and operator's cab (8) and draw positioning line n. a Stick tapes [6] to the right, left, and lower parts of the right side window glass, left side rear window glass, and door lower window glass for accurate positioning. 3) Cut the tape between window glass (9) and operator's cab (8) with a knife, and then remove the window glass. a Do not remove the tapes left on the window glass and operator's cab before installing the window glass.
OPERATOR’S CAB GLASS (STUCK GLASS)
a When positioning front window glass (4), set its horizontal position to the frame width and set its vertical position so that height difference (p) between it and the frame top will be 3 mm.
6. Apply adhesive. a Use either of the 2 types of the adhesive. 2 Adhesive (Summer): SUNSTAR PENGUINE SEAL 580 SUPER "S" 2 Adhesive (Winter): SUNSTAR PENGUINE SEAL 580 SUPER "W" a The using limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit. a Keep the adhesive in a dark place where the temperature is below 25°C. a Never heat the adhesive higher than 30°C. a When reusing the adhesive, remove the all hardened part from the nozzle tip. 1) Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle.
30-142 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
2) Cut the tip of the adhesive nozzle (14) so that dimensions (q) and (r) will be as follows. • Dimension (q): 10 mm • Dimension (r) : 15 mm
3) Set adhesive cartridge (12) to caulking gun [7]. a An electric caulking gun is more efficient.
OPERATOR’S CAB GLASS (STUCK GLASS)
a Apply adhesive (15) to dimensions (s) and (t) of both-sided adhesive tape (6) of operator's cab (8). • Dimension (s) : 10 mm • Dimension (t) : 15 mm a Apply adhesive (15) higher than bothsided adhesive tape (6). a Apply the adhesive evenly.
a Apply adhesive (15) additionally for additional both-sided adhesive tape (6a) of the right side window glass and additional both-sided adhesive tape (6b) of door lower window glass.
4) Remove the release tape of the both-sided adhesive tape on the glass side. 5) Apply adhesive (15) to the outside of bothsided adhesive tape (6) of the operator's cab.
PC750, 800-7
30-143 (2)
DISASSEMBLY AND ASSEMBLY
7. Install the window glass. 1) Install window glass (9), matching it to the lines of the positioning tapes drawn in step 5. a Since the window glass cannot be removed and stuck again, stick it very carefully. a Stick the glass within 5 minutes after applying the adhesive. 2) After sticking window glass (9), press all around it until it is stuck to the both-sided adhesive tape. a Press the corners of the window glass firmly.
OPERATOR’S CAB GLASS (STUCK GLASS)
a After installing front window glass (4), fill the clearances between it and center trim seal (16) with caulking material in range (s) to dimensions (t) and (u). After applying the primer to glass (4) of section A – A, apply adhesive as caulking material. • Caulking dimension (t) : 2 mm • Caulking dimension (u) : 5 mm a When caulking, mask the glass side and form the adhesive with a rubber spatula as shown in the figure. a Wipe off projected adhesive. 2 Glass primer: SUNSTAR GLASS PRIMER 580 SUPER 2 Adhesive: SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"
a You can perform this work efficiently by pulling window glass (9) from inside of the operator's cab with suction cup Y1.
30-144 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
8. Fix the window glass. 1) After installing right window glass (1) to the operator's cab, insert stopper rubbers Y2 to 2 places (v) at the bottom of the glass to fix the glass.
OPERATOR’S CAB GLASS (STUCK GLASS)
9. After installing the window glass, remove the primer and adhesive from the operator's cab and window glass. a Using white gasoline, wipe off the adhesive before it is dried up. a When cleaning the glass, do not give an impact to it. 10. Protect the stuck window glass. 1) Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours (at temperature of 20°C and humidity of 60%). 2) After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait at least 14 hours, at least 24 hours in total, before operating the machine actually.
2) Using styrene foam blocks [9] and rubber bands [10], fix the window glass and bothsided adhesive tape to fit them completely.
PC750, 800-7
30-145 (2)
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY k
Lower the work equipment to the ground and stop the engine. a To replace the front window glass, the front window assembly must be removed from the operator's cab. The procedure for removing and installing the front window assembly (front frame and front window glass) is explained below.
5. Release the rear locks. 6. Lower the front window assembly carefully a little. Put out rollers (8) and (9) under the both sides of the front window through the portion from which the corner blocks were removed in step 3 (the portion where the rail is open) and hold them.
REMOVAL 1. Raise the front window assembly to the ceiling and fix it with the rear locks (on both sides).
7. Remove rollers (8) and (9) under the both sides of the front window.
2. Remove left corner blocks (1) and (2) and right corner block (3). 3. Remove left striker bolt (4), right striker bolt (5), left corner block bracket, and right corner block bracket (7). 4. Install left striker bolt (4) to the operator's cab again and tighten it lightly. a This bolt will be used to hang the pull-up assist cable in step 8.
30-146 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
8. Remove left lower pin (10). a If left lower pin (10) is removed, plate (12) at the end of pull-up assist cable (11) comes off. a Hang plate (12) on the left striker bolt. k The return load of 58.8 N {6 kg} is applied to the rear of the operator's cab. Accordingly, take care when removing left lower pin (10) to disconnect pull-up assist cable (11).
FRONT WINDOW
10. Lower front window assembly (13) completely. a Do not let the front window assembly touch the monitor.
11. Twist front window assembly (13) to the right and left to remove both upper rollers (14) and (15) from the rails, and then remove front window assembly (13).
9. Put out the bottom of front window assembly (13) through the rail opening portion and lower it gradually.
PC750, 800-7
30-147 (2)
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
INSTALLATION •
Carry out installation in the reverse order to removal.
•
Adjust opening and closing of the front window assembly according to the following procedure.
1. 1.Open and close the front window to check that it does not interfere with the rails and the rollers are not hitch. 2. If there is any problem in opening or closing of the front window, loosen the mounting bolts of roller adjustment brackets (16) and (17) and adjust the condition of the front window, and then tighten the mounting bolts again. 3 Mounting bolt: 98 Nm {1.0 kgm}
30-148 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
3. Raise the front window assembly and fix it with the rear locks (on both sides). a Check that the locks in the rear of the operator's cab are applied securely. 4. Install right corner block (3) and fix right corner block bracket (7) with right striker bolt (5). a Tighten the striker bolt securely after adjusting it in step 6. a Install the right corner block so that there will be no level difference at part (a). a Install the right corner block so that level difference (b) between the rail and right corner block (3) at part PF will be 0 – 1.0 mm. Check that the right corner block is not projected from the rail at the rolling surface of the roller. a Secure roller clearance (c) at part PJ.
PC750, 800-7
FRONT WINDOW
5. Install left corner blocks (1) and (2) and secure left corner bracket (6) with left striker bolt (4). a Tighten the striker bolt securely after adjusting it in step 6. a Install the left corner blocks so that there will be no level difference at 2 part (d). a Secure roller clearance (e).
30-149 (2)
DISASSEMBLY AND ASSEMBLY
6. Tighten left striker bolt (4) and right striker bolt (5) at roughly right positions so that front window glass (18) will be fitted to cab-side trim seal (19).
FRONT WINDOW
7. Open and close the front window assembly and check the working condition of both locks (20) and (21). 1) If both locks do not work normally, move the striker bolts toward the rear of the cab and tighten them again. 2) After moving the striker bolts, check the fitness of the front window glass and cab-side trim seal which was checked in step 6. 3) Repeat the work in 1) and 2) until the fitness of the front window and the working condition of both locks (20) and (21) are acceptable, and then tighten the striker bolts.
8. After adjusting the striker bolts, splash water heavily over the front window glass and check that the water does not leak into the cab. 9. Adjust the "opening" lock of the front window assembly. 1) After adjusting the "closing" lock of the front window in steps 6 and 7, raise the front window assembly to the ceiling. 2) Check the working condition of both front window assembly "opening" locks in the rear of the operator's cab. 3) If the locks do not work normally, move both striker plates (22) in the rear of the operator's cab forward and in reverse and fix them at places where the locks work normally.
30-150 (2)
PC750, 800-7
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
10. Adjust the front window stoppers. 1) After adjusting "closing" lock of the front window assembly in step 9, check the contact of both front window stoppers (23). 2) If both stoppers (23) do not contact normally, adjust and fix them at places where they contact normally.
11. Check the latching effort of the front window assembly. 1) After finishing steps 6 – 10, check that latching efforts of both locks (20) and (21) are even. a Check the latching efforts on both "closing" side (in the front of the operator's cab) and "opening" side (in the rear of the operator's cab).
3 Left lower pin: 27 – 34 Nm {2.75 – 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
PC750, 800-7
30-151 (2)
DISASSEMBLY AND ASSEMBLY
COUNTERWEIGHT
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY REMOVAL
INSTALLATION
1. Set chain to lifting hook of counterweight assembly, and sling.
•
Carry out installation in the reverse order to removal.
2. Remove mounting bolts (1). a Adjust the stepped difference (top and bottom clearance) from the bodywork with shims. a Install so that the clearance between the counterweight and the revolving frame is 15 mm, and so that the stepped difference is uniform on the left and right. 3 Counterweight mounting bolt: 3,822 ± 392 Nm {390 ± 40 kgm}
3. Lift off counterweight assembly (2). 4
30-152 (2)
Counterweight assembly: 12,000 kg (PC800) 9,800 kg (PC750)
PC750, 800-7
90 OTHERS HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................90- 3 PC750-7, PC750SE-7 PC800-7, PC800SE-7 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................90- 5 LOADING SHOVEL SPECIFICATION PC750-7, PC750SE-7 ELECTRICAL CIRCUIT DIAGRAM (1/6) ......................................................................................................90- 7 PC750-7, PC750SE-7 PC800-7, PC800SE-7 ELECTRICAL CIRCUIT DIAGRAM (2/6) ......................................................................................................90- 9 PC750-7, PC750SE-7 PC800-7, PC800SE-7 ELECTRICAL CIRCUIT DIAGRAM (3/6) ......................................................................................................90- 11 PC750-7, PC750SE-7 PC800-7, PC800SE-7 ELECTRICAL CIRCUIT DIAGRAM (4/6) ......................................................................................................90- 13 PC750-7, PC750SE-7 PC800-7, PC800SE-7 ELECTRICAL CIRCUIT DIAGRAM (5/6) ......................................................................................................90- 15 PC750-7, PC750SE-7 PC800-7, PC800SE-7 ELECTRICAL CIRCUIT DIAGRAM (5/6) ......................................................................................................90- 17 LOADING SHOVEL SPECIFICATION PC750-7, PC750SE-7
PC750, 800-7
90-1 (3)
HYDRAULIC CIRCUIT DIAGRAM PC750-7, PC750SE-7 PC800-7, PC800SE-7
PC750, 800-7
90-3 (3)
HYDRAULIC CIRCUIT DIAGRAM LOADING SHOVEL SPECIFICATION PC750-7, PC750SE-7
PC750, 800-7
90-5 (3)
ELECTRICAL CIRCUIT DIAGRAM (1/6) PC750-7, PC750SE-7 PC800-7, PC800SE-7
PC750, 800-7
90-7 (3)
ELECTRICAL CIRCUIT DIAGRAM (2/6) PC750-7, PC750SE-7 PC800-7, PC800SE-7
PC750, 800-7
90-9 (3)
ELECTRICAL CIRCUIT DIAGRAM (3/6) PC750-7, PC750SE-7 PC800-7, PC800SE-7
PC750, 800-7
90-11 (3)
ELECTRICAL CIRCUIT DIAGRAM (4/6) PC750-7, PC750SE-7 PC800-7, PC800SE-7
PC750, 800-7
90-13 (3)
ELECTRICAL CIRCUIT DIAGRAM (5/6) PC750-7, PC750SE-7 PC800-7, PC800SE-7
PC750, 800-7
90-15 (3)
ELECTRICAL CIRCUIT DIAGRAM (6/6) LOADING SHOVEL SPECIFICATION PC750-7, PC750SE-7
PC750, 800-7
90-17 (3)
