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SEBM025303

MACHINE MODEL SERIAL NUMBER

PC750-6 11001 and up


PC750SE-6 11001 and up
PC750LC-6 11001 and up
PC800-6 31001 and up
PC800SE-6 31001 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, 800-6 mount the SAA6D140E-3 engine.


For details of the engine, see the 6D140-3 Series Engine Shop Manual.

© 2003 1
All Rights Reserved
00-1
Printed in Japan 05-03(01) (3)
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........................................................................... 90-1

00-2 PC750, 800-6


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LIST OF REVISED PAGES

The affected pages are indicated by the use of the


following marks. It is requested that necessary actions Mark Indication Action required
be taken to these pages according to the table below.
fi Page to be newly added Add

‡ Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised


or made additions.

LIST OF REVISED PAGE

Time of Time of Time of Time of Time of


Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision

‡ 00- 1 (3) 01- 1 10-10 10-39 10-70


00- 2 (1) ‡ 01- 2 (3) 10-11 10-40 10-71
‡ 00- 2-1 (3) 01- 3 10-12 10-42 10-72
‡ 00- 2-2 (3) fi 01- 3-1 (3) 10-13 10-43 10-73
‡ 00- 2-3 (3) fi 01- 3-2 (3) 10-14 10-44 10-74
‡ 00- 2-4 (3) ‡ 01- 4 (3) 10-15 10-45 10-75
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‡ 00- 4 01- 6 10-17 10-47 10-77
‡ 00- 5 01- 7 10-18 10-48 10-78
‡ 00- 6 01- 8 10-19 10-49 10-79
‡ 00- 7 01- 9 10-20 10-50 10-80
‡ 00- 8 fi 01- 9-1 (3) 10-21 10-51 10-81
‡ 00- 9 fi 01- 9-2 (3) 10-22 10-52 10-82
‡ 00-10 01-10 10-23 10-53 10-83
‡ 00-11 01-11 10-24 10-54 10-84
‡ 00-12 01-12 10-26 10-55 10-85
‡ 00-13 01-13 10-27 10-56 10-86
‡ 00-14 01-14 10-28 10-57 10-87
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‡ 00-17 10- 1 10-31 10-60 10-90
‡ 00-18 10- 2 10-32 10-62 10-91
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‡ 00-20 10- 4 10-34 10-64 10-93
‡ 00-21 10- 5 10-35 10-65 10-94
‡ 00-22 10- 6 10-36 10-66 10-95
10- 7 10-37 10-68 10-96
10- 8 10-38 10-69 10-97

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LIST OF REVISED PAGES

Time of Time of Time of Time of Time of


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10-98 10-131 20- 6 20-47 20-111


10-99 10-132 20- 7 20-48 20-112
10-100 10-133 ‡ 20- 8 (3) 20-49 20-113
10-101 10-134 ‡ 20- 9 (3) 20-50 20-114
10-102 10-135 ‡ 20-10 (3) 20-51 20-115
10-103 10-136 20-11 20-52 20-116
10-104 10-137 20-12 20-53 20-117
10-105 10-138 20-13 20-54 20-118
10-106 10-139 20-14 20-55 20-119
‡ 10-108 (3) 10-140 20-15 20-56 20-120
10-109 10-141 20-16 20-57 20-121
10-110 10-142 20-17 20-58 20-122
10-111 10-143 20-18 20-59 20-123
fi 10-111-1 (3) 10-144 20-19 20-60 20-124
fi 10-111-2 (3) 10-145 20-20 20-61 20-125
fi 10-111-3 (3) 10-146 20-21 20-62 20-126
fi 10-111-4 (3) 10-147 20-22 20-63 20-127
‡ 10-112 (3) 10-148 20-23 20-64 20-128
10-113 10-149 20-24 20-65 20-129
10-114 10-150 20-25 20-66 20-130
10-115 10-151 20-26 20-67 20-131
fi 10-115-1 (3) 10-152 20-28 20-68 20-132
fi 10-115-2 (3) 10-153 20-29 20-69 20-133
fi 10-115-3 (3) 10-154 20-30 20-70 20-134
fi 10-115-4 (3) 10-155 20-31 20-71 (2) 20-135
10-116 10-156 20-32 20-72 20-136
10-117 10-157 20-33 20-73 20-137
10-118 10-158 20-34 20-74 20-138
10-119 10-159 20-35 20-75 20-139
10-120 10-160 20-36 20-140
10-121 10-161 20-37 20-101 20-141
10-122 10-162 20-38 20-102 20-142
10-123 10-163 20-39 20-103 20-143
10-124 20-40 20-104 20-144
10-125 20-41 20-105 20-145
10-126 20- 1 20-42 20-106 20-146
10-127 20- 2 20-43 20-107 20-147
10-128 20- 3 20-44 20-108 20-148
10-129 20- 4 20-45 20-109 20-149
10-130 20- 5 20-46 20-110 20-150

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LIST OF REVISED PAGES

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20-156 20-269 20-407 20-447 20-569
20-157 20-270 20-408 20-448 20-570
20-158 20-271 20-409 20-449 20-571
20-159 20-272 20-410 20-550 20-572
20-160 20-273 20-411 20-573
20-161 20-274 20-412 20-501 20-574
20-162 20-275 20-413 20-502 20-575
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20-164 20-277 20-415 20-504 20-577
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20-279 20-417 20-506 20-579
20-201 20-280 20-418 20-507 20-580
20-202 20-281 20-419 20-508
20-203 20-282 20-420 20-509 20-601
20-204 20-283 20-421 20-510 20-602
20-205 20-284 20-422 20-511 20-603
20-206 20-285 20-423 20-512 20-604
20-207 20-286 20-424 20-513 20-605
20-208 20-287 20-425 20-514 20-606
20-209 20-288 20-426 20-515 20-607
20-210 20-289 20-427 20-516 20-608
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20-252 20-292 20-430 20-552 20-611
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20-258 20-298 20-436 20-558 20-617
20-259 20-299 20-437 20-559 20-618
20-260 20-300 20-438 20-560 20-619
20-261 20-301 20-439 20-561 20-620
20-262 20-302 20-440 20-562 20-621
20-263 20-441 20-563 20-622

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LIST OF REVISED PAGES

Time of Time of Time of Time of Time of


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20-623 30-18 (1) 30-58 (1) 30-99 (1) 30-139 (1)


20-624 30-19 (1) 30-59 (1) 30-100 (1) 30-140 (1)
20-625 30-20 (1) 30-60 (1) 30-101 (1) 30-141 (1)
20-626 30-21 (1) 30-61 (1) 30-102 (1) 30-142 (1)
20-627 30-22 (1) 30-62 (1) 30-103 (1) 30-143 (1)
20-628 30-23 (1) 30-63 (1) 30-104 (1) 30-144 (1)
20-629 30-24 (1) 30-64 (1) 30-105 (1) 30-145 (1)
20-630 30-25 (1) 30-65 (1) 30-106 (1) 30-146 (1)
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20-632 30-27 (1) 30-67 (1) 30-108 (1) 30-148 (1)
20-633 30-28 (1) 30-68 (1) 30-109 (1) 30-149 (1)
20-634 30-29 (1) 30-69 (1) 30-110 (1) 30-150 (1)
20-635 30-30 (1) 30-70 (1) 30-111 (1)
20-636 30-31 (1) 30-71 (1) 30-112 (1)
20-637 30-32 (1) 30-72 (1) 30-113 (1) 90- 1
20-638 30-33 (1) 30-73 (1) 30-114 (1) 90- 3
20-639 30-34 (1) 30-74 (1) 30-115 (1) 90- 5
20-640 30-35 (1) 30-75 (1) 30-116 (1) 90- 7
20-641 30-36 (1) 30-76 (1) 30-117 (1) 90- 9
20-642 30-37 (1) 30-77 (1) 30-118 (1) 90-11
20-643 30-38 (1) 30-78 (1) 30-119 (1)
30-39 (1) 30-79 (1) 30-120 (1)
30-40 (1) 30-80 (1) 30-121 (1)
30- 1 (1) 30-41 (1) 30-81 (1) 30-122 (1)
30- 2 (1) 30-42 (1) 30-82 (1) 30-123 (1)
30- 3 (1) 30-43 (1) 30-83 (1) 30-124 (1)
30- 4 (1) 30-44 (1) 30-84 (1) 30-125 (1)
30- 5 (1) 30-45 (1) 30-85 (1) 30-126 (1)
30- 6 (1) 30-46 (1) 30-86 (1) 30-127 (1)
30- 7 (1) 30-47 (1) 30-87 (1) 30-128 (1)
30- 8 (1) 30-48 (1) 30-88 (1) 30-129 (1)
30- 9 (1) 30-49 (1) 30-89 (1) 30-130 (1)
30-10 (1) 30-50 (1) 30-90 (1) 30-131 (1)
30-11 (1) 30-51 (1) 30-91 (1) 30-132 (1)
30-12 (1) 30-52 (1) 30-92 (1) 30-133 (1)
30-13 (1) 30-53 (1) 30-93 (1) 30-134 (1)
30-14 (1) 30-54 (1) 30-94 (1) 30-135 (1)
30-15 (1) 30-55 (1) 30-95 (1) 30-136 (1)
30-16 (1) 30-56 (1) 30-96 (1) 30-137 (1)
30-17 (1) 30-57 (1) 30-98 (1) 30-138 (1)

00-2-4 PC750, 800-6


(3)
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 ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep


tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.

00-3
SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
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
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 judge-
ments. 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 fur-
ther 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 under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance 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 com-
ponent, 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

W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:

Chassis volume: Issued for every machine model REVISIONS


Engine volume: Issued for each engine series
Revised pages are shown in the LIST OF REVISED

}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: · volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.

DISTRIBUTION AND UPDATING


Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
¤ Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-

4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting

3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special

2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with

5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or

6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204

00-6
FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING

¤ Heavy parts (25 kg or more) must be lifted


Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and

4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol

• 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 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.

¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 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,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.

★ The allowable load value is estimated to be one-


sixth 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

¤ Before carrying out the following work, release


the residual pressure from the hydraulic tank.
Type 1

For details, see TESTING AND ADJUSTING,


Releasing residual pressure from hydraulic

¤
tank.

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 hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
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
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly

3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.

• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection

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

• Used to prevent rubber gaskets,


LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.

• Used in places requiring an imme-


diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.

• Features: Resistance to heat and


LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.

Adhesive: • Used as adhesive or sealant for


790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives

Polyethylene • Used as sealant for machined


LT-4 790-129-9040 250 g holes.
container

Holtz • Used as heat-resisting sealant for


MH 705 790-126-9120 75 g Tube repairing engine.

• Quick hardening type adhesive


Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.

• Quick hardening type adhesive


• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.

Loctite Polyethylene • Resistance to heat, chemicals


79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.

• Used as adhesive or sealant for


LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.

• Used as sealant for various


threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.

• Features: Silicon based, resist-


ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.

00-10
FOREWORD COATING MATERIALS

Category Komatsu code Part No. Q'ty Container Main applications, featuresr

• Ftures: Silicon based, quick hard-


ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.

Three bond • Used as heat-resisting sealant for


790-129-9090 100 g Tube repairing engine.
1211

• Used as lubricant for sliding por-


LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.

SYG2-400LI • General purpose type


SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI

SYG2-400CA • Used for normal temperature,


Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA

Molybdenum 400 g • Used for places with heavy load


disulphide SYG2-400M (10 per Belows type
lubricant case)

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.

Thread diameter Width across


of bolt flats

mm mm Nm kgm

6 10 13.2 0 1.4 1.35 0 0.15


8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5

27 41 1320 0 140 135 0 15


30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35

Thread diameter Width across


of bolt flats

mm mm Nm kgm

6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8

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
SAD00483
the table below.
Thread diameter Width across flat Tightening torque

mm mm Nm kgm

14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0

00-12
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 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0

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 Tightening torque


Norminal No.
mm mm Nm kgm

02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5

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 Tightening torque


Norminal No.
mm mm Nm kgm

08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 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
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 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
6 8 20 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 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
1 / 16 3 10 0.31 0 0.10
1/8 8 20 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 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.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) (mm) (Reference)
inch, Thread series
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(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 – –

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
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal


etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 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

CLASSIFICATION BY COLOR AND CODE

Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication

Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue

Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White

Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow

Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow

Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black

Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue 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.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters 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

0 1 2 3 4 5 6 7 8 9

0 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

C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
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

00-16
FOREWORD CONVERSION TABLE

Millimeters to Inches
1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 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

Kilogram to Pound
1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0 0 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 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

Liter to U.K. Gallon


1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0 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

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 Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn 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 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8


–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8


–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8


–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8


–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0


–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0


–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0


–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

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, 800-6 01-1


GENERAL SPECIFICATION DRAWINGS

SPECIFICATION DRAWINGS
BACKHOE SPECIFICATION
DIMENSIONS

WORKING RANGES

01-2 PC750, 800-6


(3)
GENERAL SPECIFICATION DRAWINGS

DIMENSIONS
Item Unit PC750-6 PC750SE-6 PC750LC-6 PC800-6 PC800SE-6

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 3,520 3,520 3,520 3,620 3,620

F Tail swing radius mm 4,245 4,245 4,245 4,245 4,245

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

WORKING RANGES
Working range (mm) PC750-6 PC750SE-6 PC750LC-6 PC800-6 PC800SE-6

A Max. digging reach 13,740 12,265 13,740 13,660 12,265

B Max. digging depth 8,600 7,130 8,600 8,445 7,130

C Max. digging height 11,840 11,330 11,840 11,955 11,330

D Max. vertical wall depth 5,575 4,080 5,575 5,230 4,080

E Max. dumping height 8,145 7,525 8,145 8,235 7,525

F Max. reach at ground level 13,460 11,945 13,460 13,400 11,945

PC750, 800-6 01-3


GENERAL SPECIFICATION DRAWINGS

LOADING SHOVEL SPECIFICATION


DIMENSIONS

WORKING RANGES

01-3-1 PC750, 800-6


(3)
GENERAL SPECIFICATION DRAWINGS

DIMENSIONS
PC750-6 (Loading shovel specification)
Item Unit
with bucket link without bucket link

A Overall length mm 9,900 9,865

B Overall height mm 5,115 5,640

C Overall width mm 4,110 4,110

D Track shoe width mm 610 610

E Height of machine cab mm 3,520 3,520

F Tail swing radius mm 4,245 4,245

G Track overall length mm 5,810 5,810

H Length of track on ground mm 4,500 4,500

— Min. ground clearance mm 840 840

WORKING RANGES
PC750-6 (Loading shovel specification)
Item Unit
with bucket link without bucket link

A Max. digging reach mm 10,155 10,305

B Max. reach at ground level mm 9,765 9,920

C Max. digging height mm 10,560 10,635

D Max. digging depth mm 3,390 3,535

E Min. reach at ground level mm 5,680 5,620

F Min. swing radius of work equipment mm 6,115 5,980

PC750, 800-6 01-3-2


(3)
GENERAL SPECIFICATIONS

SPECIFICATIONS
BACKHOE SPECIFICATION
Machine model PC750-6 PC750SE-6
Serial Number 11001 and up 11001 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
Working ranges

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


Performance

Max. dumping height mm 8,145 7,525


Max. digging force 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: 2.7 Low speed: 2.7
High speed: 4.2 High speed: 4.2

Gradeability deg. 35 35
Ground pressure (standard double
grouser shoe width: 710 mm) kPa {kg/cm2} 101.01 {1.03} 102.97 {1.05}

Overall length mm 14,305 13,030

Overall width mm 4,325 4,325

Overall width of track (when extended) 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


Dimensions

Ground clearance of upper structure mm 1,560 1,560


Min. ground clearance mm 840 840

Tail swing radius mm 4,245 4,245

Min. swing radius of work equipment mm 6,060 5,645


Height of work equipment at min. swing radius 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 3,520 3,520

01-4 PC750, 800-6


(3)
GENERAL SPECIFICATIONS

Machine model PC750-6 PC750SE-6


Serial Number 11001 and up 11001 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 x stroke mm 6 – 140 x 165
Piston displacement ¬ {cc} 15.24 {15,240}
Flywheel horsepower kW/rpm {HP/rpm} 338/1,800 {454/1,800}
Performance
Engine

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} 200 {149}
Starting motor 24V, 11 kW
Alternator 24V, 50A
Battery 12V, 170 Ah x 2
Radiator core type CWX-4
Carrier roller 3 on each side
carriage
Under-

Track roller 8 on each side


Track shoe Assembly-type double grouser, 47 on each side
Type Variable displacement piston type:
Hydraulic

HPV95+95, HPV95+95; gear type SAR80+8


pump

Delivery ¬/min Piston type: 490+490, gear type: 136+16


2
Set pressure MPa {kg/cm } Piston type: 31.4 {320}, gear type: 2.9 {30}
Control

Type x No. 4-spool + 5-spool type x 1


valve

Control method Hydraulic


Travel motor Piston type (with brake valve, shaft brake):
Hydraulic

x 2 (MSF-340VP)
motor
Hydraulic system

Swing motor Piston type (with safety valve, shaft brake):


x 2 (KMF125AB-5)

Arm Bucket
Boom
PC750-6 PC750SE-6 PC750-6 PC750SE-6
Hydraulic cylinder

Cylinder type Double-acting piston


Inside diameter of cylinder mm 200 200 180 180 225
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 Box-shaped, sealed with breather
Hydraulic filter Tank return side
Hydraulic cooler Air cooled (J4)

PC750, 800-6 01-5


GENERAL SPECIFICATIONS

Machine model PC750LC-6


Serial Number 11001 and up

Bucket capacity m3 3.1

Weight of machine kg 75,840


Max. digging depth mm 8,600
Working ranges

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


Performance

Max. dumping height mm 8,145


Max. digging force kN {kg} 333.4 {34,000}

Swing speed rpm 6.8

Swing max. slope angle deg. 16


Travel speed km/h Low speed: 2.7
High speed: 4.2

Gradeability deg. 35

Ground pressure (standard double


grouser shoe width: 810 mm) kPa {kg/cm2} 91.6 {0.935}

Overall length mm 14,305

Overall width mm 4,455

Overall width of track (when extended) mm 4,310


Overall height mm 4,660

Overall height to top of machine mm 4,000


Dimensions

Ground clearance of upper structure mm 1,560


Min. ground clearance mm 840

Tail swing radius mm 4,245

Min. swing radius of work equipment mm 6,060


Height of work equipment at min. swing radius mm 10,855

Length of track on ground mm 5,020

Track gauge (when extended) mm 3,500


Height of machine cab mm 3,515

01-6 PC750, 800-6


GENERAL SPECIFICATIONS

Machine model PC750LC-6


Serial Number 11001 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 x stroke mm 6 – 140 x 165


Piston displacement ¬ {cc} 15.24 {15,240}
Flywheel horsepower kW/rpm {HP/rpm} 338/1,800 {454/1,800}
Performance

Max. torque Nm/rpm {kgm/rpm} 2,138/1,350 {218/1,350}


Max. speed at no load rpm 1,980
Engine

Min. speed at no load rpm 825


Min. fuel consumption g/kWh {g/HPh} 200 {149}
Starting motor 24V, 11 kW
Alternator 24V, 50A
Battery 12V, 170 Ah x 2
Radiator core type CWX-4
Carrier roller 3 on each side
Track roller 9 on each side
Track shoe Assembly-type double grouser, 51 on each side
Type Variable displacement piston type:
Hydraulic
carriage
Under-

HPV95+95, HPV95+95; gear type SAR80+8


pump

Delivery ¬/min Piston type: 490+490, gear type: 136+16


Set pressure MPa {kg/cm2} Piston type: 31.4 {320}, gear type: 2.9 {30}
Control

Type x No. 4-spool + 5-spool type x 1


valve

Control method Hydraulic


Travel motor Piston type (with brake valve, shaft brake):
Hydraulic

x 2 (MSF-340VP)
motor

Swing motor Piston type (with safety valve, shaft brake):


x 2 (KMF125AB-5)
Hydraulic system

Boom Arm Bucket


Hydraulic cylinder

Cylinder type 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 Air cooled (J4)

PC750, 800-6 01-7


GENERAL SPECIFICATIONS

Machine model PC800-6 PC800SE-6


Serial Number 31001 and up 31001 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
Working ranges

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


Performance

Max. dumping height mm 8,235 7,525


Max. digging force 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: 2.7 Low speed: 2.7
High speed: 4.2 High speed: 4.2

Gradeability deg. 35 35

Ground pressure (standard double


grouser shoe width: 710 mm) kPa {kg/cm2} 106.89 {1.09} 105.91 {1.08}

Overall length mm 13,895 13,030

Overall width mm 4,325 4,325

Overall width of track (when extended) 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


Dimensions

Ground clearance of upper structure mm 1,560 1,560


Min. ground clearance mm 840 840

Tail swing radius mm 4,245 4,245

Min. swing radius of work equipment mm 5,985 5,645


Height of work equipment at min. swing radius 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 3,620 3,620

01-8 PC750, 800-6


GENERAL SPECIFICATIONS

Machine model PC800-6 PC800SE-6


Serial Number 31001 and up 31001 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 x stroke mm 6 – 140 x 165
Piston displacement ¬ {cc} 15.24 {15,240}
Flywheel horsepower kW/rpm {HP/rpm} 338/1,800 {454/1,800}
Performance
Engine

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} 200 {147}
Starting motor 24V, 11 kW
Alternator 24V, 50A
Battery 12V, 170 Ah x 2
Radiator core type CWX-4
Carrier roller 3 on each side
carriage
Under-

Track roller 8 on each side


Track shoe Assembly-type double grouser, 47 on each side
Type Variable displacement piston type:
Hydraulic
pump

HPV95+95, HPV95+95; gear type SAR80+8


Delivery ¬/min Piston type: 490+490, gear type: 136+16
2
Set pressure MPa {kg/cm } Piston type: 31.4 {320}, gear type: 2.9 {30}
Control

Type x No. 4-spool + 5-spool type x 1


valve

Control method Hydraulic


Travel motor Piston type (with brake valve, shaft brake):
Hydraulic
motor

x 2 (MSF-340VP)
Swing motor Piston type (with safety valve, shaft brake):
Hydraulic system

x 2 (KMF125AB-5)
Bucket
Boom Arm
PC800-6 PC800SE-6
Hydraulic cylinder

Cylinder type Double-acting piston


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 Box-shaped, sealed with breather
Hydraulic filter Tank return side
Hydraulic cooler Air cooled (J4)

PC750, 800-6 01-9


GENERAL SPECIFICATIONS

LOADING SHOVEL SPECIFICATION


PC750-6
Machine model
with bucket link without bucket link

Serial Number 11001 and up

Bucket capacity m3 3.8 4.5


Weight of machine kg 75,810 76,110

Max. digging depth mm 3,390 3,535


Working ranges

Max. vertical wall depth mm — —


Max. digging reach mm 10,155 10,305

Max. reach at ground level mm 9,765 9,920

Max. digging height mm 10,560 10,635


Performance

Max. dumping height mm 6,840 7,180

Max. digging force kN {kg} 431.5 {44,000} 476.3 {48,600}

Swing speed rpm 5.7 5.7


Swing max. slope angle deg. 14 14

Travel speed km/h Low speed: 2.7 Low speed: 2.7


High speed: 4.2 High speed: 4.2

Gradeability deg. 35 35

Ground pressure (standard double


grouser shoe width: 610 mm) kPa {kg/cm2} 122.2 {1.25} 122.7 {1.25}

Overall length mm 9,900 9,865

Overall width mm — —
Overall width of track (when extended) mm 3,490 (4,210) 3,490 (4,210)

Overall height mm 5,115 5,640

Overall height to top of machine mm 4,000 4,000


Dimensions

Ground clearance of upper structure mm 1,560 1,560

Min. ground clearance mm 840 840

Tail swing radius mm 4,310 4,310


Min. swing radius of work equipment mm 6,115 6,340

Height of work equipment at min. swing radius mm 7,135 7,090

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 3,445 3,445

01-9-1 PC750, 800-6


(3)
GENERAL SPECIFICATIONS

PC750-6
Machine model
with bucket link without bucket link
Serial Number 11001 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 x stroke mm 6 – 140 x 165
Piston displacement ¬ {cc} 15.24 {15,240}
Flywheel horsepower kW/rpm {HP/rpm} 338/1,800 {454/1,800}
Performance
Engine

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} 200 {149}
Starting motor 24V, 11 kW
Alternator 24V, 50A
Battery 12V, 170 Ah x 2
Radiator core type CWX-4
Carrier roller 3 on each side
carriage
Under-

Track roller 8 on each side


Track shoe Assembly-type double grouser, 47 on each side
Type Variable displacement piston type:
Hydraulic

HPV95+95, HPV95+95; gear type SAR80+8


pump

Delivery ¬/min Piston type: 490+490, gear type: 136+16


Set pressure MPa {kg/cm2} Piston type: 31.4 {320}, gear type: 2.9 {30}
Control

Type x No. 4-spool + 5-spool type x 1


valve

Control method Hydraulic


Travel motor Piston type (with brake valve, shaft brake):
Hydraulic

x 2 (MSF-340VP)
motor
Hydraulic system

Swing motor Piston type (with safety valve, shaft brake):


x 2 (KMF125AB-5)

Boom Arm Bucket Bottom dump


Hydraulic cylinder

Cylinder type Double-acting piston


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 1,300 335
Max. distance between pins mm 4,240 4,130 3,750 1,235
Min. distance between pins mm 2,750 2,600 2,450 900
Hydraulic tank Box-shaped, sealed with breather
Hydraulic filter Tank return side
Hydraulic cooler Air cooled (J4)

PC750, 800-6 01-9-2


(3)
GENERAL WEIGHT TABLE

WEIGHT TABLE
¤ This weight table is a guide for use when transporting or handling components
BACK HOE
Unit: kg
Machine model PC750-6 PC750SE-6 PC750LC-6

Serial Number 11001 and up 11001 and up 11001 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

Revolving frame (incl. left and right decks) 6,960 6,960 6,960
Operator’s cab 293 293 293

Swing machinery 490 x 2 490 x 2 490 x 2

Swing motor assembly 57 x 2 57 x 2 57 x 2


Travel motor assembly 130 x 2 130 x 2 130 x 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 x 2 2,630 x 2 2,880 x 2

• Carrier roller 51.8 x 6 51.8 x 6 51.8 x 6


• Track roller 136 x 16 136 x 16 136 x 18

• Idler cushion assembly 782 x 2 782 x 2 782 x 2

• Idler 450 x 2 450 x 2 450 x 2


• Final drive assembly 1,344 x 2 1,344 x 2 1,344 x 2

• Swing circle assembly 1,405 1,405 1,405

01-10 PC750, 800-6


GENERAL WEIGHT TABLE

Unit: kg
Machine model PC750-6 PC750SE-6 PC750LC-6

Serial Number 11001 and up 11001 and up 11001 and up

Track shoe assembly


• Narrow shoe (610 mm) 7,840 7,840 7,840

• Standard shoe (710 mm) 8,540 8,540 8,540

• Wide shoe (810 mm) 9,240 9,240 10,020


• Wide shoe (910 mm) 9,920 9,920 –

• Wide shoe (1,010 mm) 10,620 10,620 11,520

• Wide shoe (1,110 mm) – – 12,270


Boom assembly (excl. piping) 7,420 6,850 7,420

Arm assembly (excl. piping) 3,035 3,944 3,035

Bucket assembly (excl. piping) 2,960 3,435 2,960


Boom cylinder assembly 790 x 2 790 x 2 790 x 2

Arm cylinder assembly 881 497 x 2 881


Bucket cylinder assembly 506 933 506

Boom foot pin 45.2 x 2 45.2 x 2 45.2 x 2

Boom cylinder foot pin 33.8 x 2 33.8 x 2 33.8 x 2


Boom cylinder top pin 32.5 x 2 32.5 x 2 32.5 x 2

Boom-arm connecting pin 105 105 105

Arm cylinder foot pin 53.6 24 x 2 53.6


Arm cylinder top pin 30 24 x 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

PC750, 800-6 01-11


GENERAL WEIGHT TABLE

Unit: kg
Machine model PC800-6 PC800SE-6

Serial Number 31001 and up 31001 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

Revolving frame (incl. left and right decks) 6,960 6,960


Operator’s cab 293 293

Swing machinery 490 x 2 490 x 2

Swing motor assembly 57 x 2 57 x 2


Travel motor assembly 130 x 2 130 x 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 x 2 2,630 x 2

• Carrier roller 51.8 x 6 51.8 x 6


• Track roller 136 x 16 136 x 16

• Idler cushion assembly 782 x 2 782 x 2

• Idler 450 x 2 450 x 2


• Final drive assembly 1,344 x 2 1,344 x 2

• Swing circle assembly 1,405 1,405

01-12 PC750, 800-6


GENERAL WEIGHT TABLE

Unit: kg
Machine model PC800-6 PC800SE-6

Serial Number 31001 and up 31001 and up

Track shoe assembly


• Narrow shoe (610 mm) 7,560 7,560

• Standard shoe (710 mm) 8,240 8,240

• 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) 3,330 3,800

Bucket assembly (excl. piping) 3,540 3,840


Boom cylinder assembly 790 x 2 790 x 2

Arm cylinder assembly 497 x 2 497 x 2


Bucket cylinder assembly 545 933

Boom foot pin 45.2 x 2 45.2 x 2

Boom cylinder foot pin 33.8 x 2 33.8 x 2


Boom cylinder top pin 32.5 x 2 32.5 x 2

Boom-arm connecting pin 105 105

Arm cylinder foot pin 24 x 2 24 x 2


Arm cylinder top pin 24 x 2 24 x 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

PC750, 800-6 01-13


GENERAL FUEL, COOLANT AND LUBRICANTS

FUEL, COOLANT AND LUBRICANTS


AMBIENT TEMPERATURE CAPACITY (¬)
KIND OF
RESERVOIR –22 –4 14 32 50 68 86 104°F
FLUID Specified Refill
–30 –20 –10 0 10 20 30 40°C

SAE 30
SAE 10W
Engine oil pan 61 55
SAE 10W-30
SAE 15W-40

SAE 30
PTO case Engine 13.5 13.5
oil SAE 10W
Swing machinery case
(front and rear) 24.5 24.5
SAE 30
Final drive case (each side) 20 20

Hydraulic system SAE 10W 800 440

Idler (1 each) 0.55 —


Gear
Track roller (1 each) oil GO 140B 0.42 —

Carrier roller (1 each) 0.62 —

ASTM D975 No. 2


Fuel tank Diesel 880 —
fuel ASTM D975A No.1

Cooling system Coolant Add antifreeze 85 —

01-14 PC750, 800-6


STRUCTURE, FUNCTION
10 AND MAINTENANCE STANDARD

PTO ................................................................ 10- 2 Straight-travel valve .................................. 10- 70


PTO Lubrication system .............................. 10- 3 Swing motor ............................................... 10- 73
Power train ................................................... 10- 4 Center swivel joint ..................................... 10- 78
Swing machinery ......................................... 10- 6 Travel motor ............................................... 10- 79
Swing circle .................................................. 10- 8 PPC control relief valve ............................. 10- 89
Final drive ..................................................... 10-10 Safety lock valve ........................................ 10- 90
Track frame and Recoil spring ................... 10-12 PPC accumulator ........................................ 10- 91
Idler ................................................................ 10-14 Valve control .............................................. 10- 92
Carrier roller ................................................. 10-16 Work equipment, swing PPC valve .......... 10- 93
Track roller .................................................... 10-17 Travel PPC valve ........................................ 10- 98
Track shoe .................................................... 10-18 Solenoid valve ............................................ 10-102
Motor grease pump ..................................... 10-23 Hydraulic cylinder ...................................... 10-108
Hydraulic tank .............................................. 10-24 Work equipment ........................................ 10-112
Hydraulic pump ............................................ 10-26 Dimensions of work equipment ............... 10-116
Line oil filter ................................................. 10-56 Air conditioner ........................................... 10-120
Pilot oil filter ................................................. 10-56 Engine control ............................................ 10-121
Drain oil filter ............................................... 10-57 Machine control system ............................ 10-126
L.H. 5-spool control valve ........................... 10-58 Monitor system .......................................... 10-154
R.H. 4-spool control valve ........................... 10-64 Sensors ....................................................... 10-161

PC750, 800-6 10-1


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PTO

PTO

1. PTO case Specifications


2. Driven gear (No. of teeth: 56) Lubricating oil: 13.5 ¬ (EO30-CD)
3. Main shaft
56
4. Hub Reduction ratio: HPV95 + 95 shaft = = 1.333
5. Connection plate 42
6. Driven gear (No. of teeth: 42) 56
HPV95 + 95 shaft = = 1.333
7. Breather 42
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 Criteria Remedy

Standard size Repair limit


Backlash of gear pump spline
8 (for SAR80 + 8)
0.273 – 0.374 —
Adjust
Backlash between drive gear and
9 driven gear (for SAL63 + 8) 0.2 – 0.74 —

Backlash of main pump spline


10 (for HPV95 + 95) 0.07 – 0.18 —

10-2 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PTO LUBRICATION SYSTEM

PTO LUBRICATION SYSTEM


Hydraulic circuit diagram

Hydraulic piping diagram

1. PTO case Outline


2. Divider block The PTO uses the SAR8 of control and PTO lu-
3. Lubricating pipe bricating pump (4). The lubricating oil inside PTO
4. Control, PTO lubricating pump (SAR80 + 8) case (1) passes through oil filter (5), is sent to
5. Oil filter top divider block (2), and is then divided to vari-
ous parts of the PTO to lubricate and cool the
gears.

PC750, 800-6 10-3


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN

POWER TRAIN

10-4 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN

1. Idler 11. No. 2 pump (HPV95 + 95)


2. Center swivel joint 12. Control, PTO lubricating pump
3. Swing motor (KMF125AB-5) 13. Swing brake solenoid valve
4. L.H. 5-spool control valve 14. Travel speed solenoid valve
5. R.H. 4-spool control valve 15. Swing machinery
6. Final drive, sprocket 16. Swing circle
7. Travel motor
8. Engine A. L.H. 5-spool control valve
9. PTO B. Swing brake solenoid valve
10. No. 1 pump (HPV95 + 95)

PC750, 800-6 10-5


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY

SWING MACHINERY

10-6 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY

1. Swing pinion
(No. of teeth: 13)
2. Cover
3. Case
4. Coupling
5. No. 2 planetary gear
(No. of teeth: 38)
6. Ring gear (No. of teeth: 97)
7. No. 1 planetary gear
(No. of teeth: 38)
8. Cover
9. Dipstick
10. Swing motor
11. No. 1 sun gear
(No. of teeth: 20)
12. No. 1 planetary carrier
13. No. 2 sun gear
(No. of teeth: 19)
14. No. 2 planetary carrier
15. Drain plug

Specification
Reduction ratio:
20 + 97 19 + 97
x = 35.716
20 19
Unit: mm

No. Check item Criteria Remedy

Standard clearance Clearance limit


Backlash between swing motor
16 shaft and No. 1 sun gear
0.19 – 0.29 —

Backlash between No. 1 sun gear


17 and No. 1 planet gear 0.19 – 0.51 0.90

Backlash between No. 1 planet gear


18 and ring gear 0.24 – 0.70 0.90

Backlash between No. 2 planet


19 carrier and coupling 0.06 – 0.24 —

Backlash between No. 1 planet


20 carrier and No. 2 sun gear 0.38 – 0.78 1.10 Replace

Backlash between No. 2 sun gear


21 and No. 2 planet gear 0.17 – 0.52 1.00

Backlash between No. 2 planet gear


22 and ring gear 0.21 – 0.64 1.10

Backlash between coupling and


23 swing pinion 0.08 – 0.25 —

Backlash between swing pinion and


24 swing circle 0 – 1.5 2.00

Clearance between plate and


25 coupling 0.06 – 0.86 —

Standard size Repair limit Repair hard


Wear of swing pinion oil seal chrome
26 contact surface
0 plating or
150 –0.100 — replace

PC750, 800-6 10-7


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING CIRCLE

SWING CIRCLE

1. Swing circle inner race (No. of teeth: 112) Specifications


2. Ball 112
Reduction ratio: – = –8.615
3. Swing circle outer race 13
Amount of grease: 75 ¬ (G2-LI)
a. Inner race soft zone “S” position
b. Outer race soft zone “plug” position

Unit: mm

No. Check item Criteria Remedy

Clearance of bearing in axial Standard clearance Repair limit


4 direction (when mounted on Replace
machine) 0.5 – 1.6 3.2

10-8 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE

FINAL DRIVE

1. Level plug 18. No. 1 planet gear (No. of teeth: 24)


2. Drain plug 19. Driven gear (No. of teeth: 69)
3. Cover 20. No. 2 ring gear (No. of teeth: 69)
4. No. 2 planetary carrier
5. No. 2 sun gear (No. of teeth: 19)
6. Drive gear (No. of teeth: 19) Specifications
7. No. 1 planetary carrier
8. No. 2 planet gear (No. of teeth: 24) Reduction ratio: – ( 12 + 69 ) × (19 + 69 )
12 19
9. Hub
69
10. Sprocket ×( ) = –113.535
19
11. Floating seal
12. Case
13. Coupling
14. No. 1 sun gear (No. of teeth: 12)
15. Travel motor
16. Idler gear (No. of teeth: 28)
17. No. 1 ring gear (No. of teeth: 69)

10-10 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE

Unit: mm

No. Check item Criteria Remedy

Standard clearance Clearance limit


Backlash between No. 2 planetary
21 carrier and case
0.08 – 0.27 —

Backlash between drive gear and No.


22 1 planetary carrier 0.21 – 0.57 —

Backlash between No. 2 sun gear


23 gear and No. 1 planetary carrier 0.24 – 0.91 —

Backlash between No. 2 sun gear


24 gear and No. 2 planet gear 0.23 – 0.68 —

Backlash between No. 2 planetary


25 carrier and No. 2 ring gear 0.28 – 0.87 —
Replace
Backlash between coupling and drive
26 gear 0.38 – 0.72 —

Backlash between No. 1 ring gear and


27 case 0.08 – 0.26 —

Backlash between No. 1 sun gear and


28 travel motor coupling 0.07 – 0.18 —

Backlash between No. 1 sun gear and


29 idler gear 0.19 – 0.62 —

Backlash between No. 1 ring gear and


30 idler gear 0.19 – 0.62 —

Backlash between driven gear and


31 No. 1 planet gear 0.19 – 0.62 —

32 Wear of sprocket tooth shape Repair limit: 6

Rebuild or
Standard size Repair limit replace
33 Sprocket tooth width
114 108

PC750, 800-6 10-11


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING

TRACK FRAME AND RECOIL SPRING


fl The diagram shows the PC750-6.

1. Idler • The dimensions and number of track rollers


2. Track frame may differ according to the model, but the
3. Carrier roller basic structure is the same.
4. Center frame
5. Final drive • No. of track rollers
6. Track roller
7. Track shoe Model No. of rollers (each side)
8. Idler cushion
PC750, 750SE-6
9. Front guard 8
PC800, 800SE-6
PC750LC-6 9

10-12 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING

Standard shoe Unit: mm


Model PC750-6 PC750SE-6 PC750LC-6 PC800-6 PC800SE-6
Item
Shoe width
(double shoe) 710 710 810 710 710

Link pitch 260.6 260.6 260.6 260.6 260.6


No. of shoes
(each side) 47 47 51 47 47

Unit: mm

No. Check item Criteria Remedy

Standard Repair
size Tolerance
limit Rebuild or
Top-to-bottom width of idler +3 replace
10 guide Track frame 185 185 –2 190

Idler support 180 185±0.5 175 Replace

– Rebuild or
Track frame 345 345 +3
–2 355 replace
11 Left-to-right width of idler
guide
Idler support 340 — 332

Standard size Repair limit


Replace
Free length Installation Installation Free Installation
12 Recoil spring × OD length load length load
489.8 kN 392 kN
1,553 × 310 1,290 (49,986 kg) — (40,000 kg)

PC750, 800-6 10-13


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER

IDLER

10-14 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit


1 Outside diameter of protruding
part
875 —

2 Outside diameter of tread surface 830 818


Rebuild or
replace
3 Depth of tread 22.5 28.5

4 Overall width 266 —

5 Width of tread 69.5 —

Tolerance
Standard Standard Clearance
Clearance between shaft and size clearance limit
6 bushing Shaft Hole

–0.120 +0.361 0.401 –


110 1.5
–0.207 +0.281 0.568 Replace
bushing
Tolerance
Standard Standard Interference
Interference between idler and size interference limit
7 bushing Shaft Hole

+0.087 –0.036 0.073 –


120 +0.037 –0.136 0.223 —

PC750, 800-6 10-15


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER

CARRIER ROLLER

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit


1 Outside diameter of flange
194 —

2 Outside diameter of tread 175 155


Rebuild or
replace
3 Width of tread 68 —

4 Thickness of tread 57.6 47.6

5 Width of flange 17 —

Tolerance
Standard Standard Interference
Interference between bearing and size interference limit
6 support Shaft Hole

–0 –0 –0.015 –
110 —
–0.015 –0.035 0.035
Replace
Interference between bearing and +0.039 –0 0.020 –
7 shaft 60 +0.020 –0.015 0.054 —

Standard clearance Clearance limit


8 Play of roller in axial direction
0 – 0.301 0.43

10-16 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER

TRACK ROLLER

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit


1 Outside diameter of flange
298 —

2 Outside diameter of tread surface 255 243

3 Thickness of tread 73.7 67.7 Rebuild or


replace
4 Overall width 328 —

5 Inside width 126 —

6 Width of tread 72 —

7 Width of flange 29 —

Tolerance
Standard Standard Clearance
Clearance between shaft and size clearance limit
8 bushing Shaft Hole

–0.140 +0.375 0.375 –


100 1.5
–0.207 +0.235 0.582 Replace
bushing
Tolerance
Standard Standard Interference
Interference between roller and size interference limit
9 bushing Shaft Hole

+0.087 +0.020 0.017 –


107.6 +0.037 –0.015 0.102 —

PC750, 800-6 10-17


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE

TRACK SHOE
(1/2)

fl P portion shows the link of bushing press fitting end.

10-18 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit


1 Link pitch
263.6 (Heavy-duty areas)
260.6 265.6 (Standard areas)
Reverse or
When turned replace
Standard size
2 Bushing outside diameter Normal load Impact load

87.5 82.5 —

Standard size Repair limit


Repair or
3 Link height
replace
156 143

Thickness of link metal


4 39.3
(bushing press-fitting portion)

5 234.95
Replace
6 Shoe bolt pitch 184.2

7 76.2

8 Inside width 133.6

Repair or
9 Link Overall width 73 replace

10 Tread width 65

11 Protrusion of pin 4.5

12 Protrusion of regular bushing 10.8

13 Overall length of pin 320.4


Adjust or
replace
14 Overall length of bushing 225.8

15 Thickness of bushing metal 15.75

16 Thickness of spacer 12.45

17 Bushing 130 – 217 kN {13.3 – 22.1 ton}

18 Press-fitting force Regular pin 312 – 350 kN {31.8 – 35.7 ton} —


ª
19 Master pim 249 – 294 kN {25.9 – 30 ton}

ª : Dry type track link

PC750, 800-6 10-19


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE

(2/2)

fl P portion shows the link of bushing press fitting end.

10-20 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE

Unit: mm

No. Check item Criteria Remedy

Tightening torque Additinal tightening


(Nm {kgm}) angle (deg.)
a. Regular link
784±78 {80±8} 120±10
Shoe bolt Retighten
Tightening torque Additinal tightening Lower limit torque
20 (Nm {kgm}) angle (deg.) (Nm {kgm})
b. Master link
— — —

No. of shoes (each side) 47 —

Tolerance
Standard Standard
size interference
21 Interference between Shaft Hole
bushing and link
+0.472 +0.087
87.5 +0.372 +0 0.285 – 0.472

Interference between +0.596 +0.074


22 regular pin and link 55.2 0.422 – 0.596
+0.496 +0

Tolerance
Standard Standard
size clearance
Clearance between Shaft Hole
23
regular pin and bushing
+0.05 +1.286 Adjust or
56 –0.05 +0.786 0.736 – 1.236
replace

Tolerance
Standard Standard
ª size interference
Interference between Shaft Hole
24
master pin and link
+0.442 +0.074
55.2 0.338 – 0.442
+0.412 +0

Tolerance
Standard Standard
ª size clearance
Clearance between Shaft Hole
25
master pin and bushing
+0.296 +1.036
56 +0.196 +0.536 0.24 – 0.84

ª : Dry type track link

PC750, 800-6 10-21


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE

DOUBLE SHOE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit


1 Height
50 25

2 Height 50

3 Thickness 20
Rebuild or
replace
4 39
Length at bottom
5 —

6 30
Length at top
7 30

10-22 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MOTOR GREASE PUMP

MOTOR GREASE PUMP

1. Motor grease pump unit Function


2. Valve • The pump unit is divided into air chamber
3. Cover (4) and grease chamber (6). As the grease
4. Air chamber level in grease chamber (6) lowers, follower
5. Follower plate plate (5) is pulled down to push down the
6. Grease chamber grease sticking to the rim of grease cham-
7. Grease tank ber (6).
8. Wing nut

PC750, 800-6 10-23


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK

HYDRAULIC TANK

1. Hydraulic tank Specifications


2. Strainer Tank capacity: 729 ¬
3. Oil filler cap Amount of oil inside tank: 482 ¬ (at H level)
4. Pressure valve
5. Suction strainer Pressure valve
6. Sight gauge Relief cracking pressure: 16.7 ± 6.9 kPa
7. Drain valve {0.17 ± 0.07 kg/cm2}
8. Hydraulic oil level sensor Suction cracking pressure: 0 – 0.49 kPa
8. Hydraulic oil temperature sensor {0 – 0.005 kg/cm2}

10-24 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

HYDRAULIC PUMP
NO. 1 PUMP ASSEMBLY

HPV95 + 95

1. Front servo valve PA1 :


Discharge port Pecn : CO, NC valve output
2. Front CO, NC valve PA2 :
Discharge port pressure detection port
3. Rear servo valve Ps :
Suction port Pd11: Drain port
4. Rear CO, NC valve Pt :
Jet sensor upstream pressure IN port Pd21: Drain port
5. TVC valve Pd :
Jet sensor downstream pressure IN PCF : CO cancelling pressure
6. Rear pump port pilot port
7. Front pump Psv : Servo basic pressure supply port PCR : CO cancelling pressure
pilot port

10-26 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

1. No. 1 main pump

Psv1 : Servo valve basic pressure port Psv2A : Servo piston output port
Psv2 : Servo valve basic pressure port Psv1B : Servo valve output port
Psv1A : Servo piston output port Psv2B : Servo valve output port

PC750, 800-6 10-27


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

1. Front shaft 6. Cylinder block 11. Rear end cap


2. Front cradle 7. Valve plate 12. Rear case
3. Front case 8. Front end cap 13. Rear cradle
4. Rocker cam 9. Impeller 14. Rear shaft
5. Piston 10. Coupling 15. Servo piston

10-28 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

2. No. 1 pump front servo assembly

1. CO, NC valve assembly Pac : Servo actuator port


2. Servo valve assembly Pc : CO selector pilot port
Pt : Jet sensor upstream pressure IN port
Pd : Jet sensor downstream pressure IN port
PA1 : Main pump pressure IN port Pecn :CO, NC valve output pressure detection
Pe2 : TVC valve output pressure front, rear port
interconnection port Pdr : Servo valve drain OUT port
Psv : Servo basic pressure IN port

PC750, 800-6 10-29


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

3. No. 1 pump rear servo assembly

1. TVC valve Pac :


Servo actuator port
2. CO, NC valve assembly Pc :
CO selector pilot port
3. Connector Pt :
Jet sensor upstream pressure IN port
4. Servo valve assembly Pd :
Jet sensor downstream pressure front,
rear interconnection port
PA1 : Main pump pressure IN port Pe : TVC valve output pressure front, rear
PA2 : Main pump pressure IN port interconnection port
Psv : Servo basic pressure IN port Pdr : Servo valve drain OUT port

10-30 PC750, 800-6


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, 800-6 10-31


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

No. 1 pump rear servo valve

PA1 : Main pump pressure OUT port Psv2 : Servo basic pressure OUT port
PA2 : Main pump pressure OUT port Pecn : CO, NC valve output pressure IN port
Pdr : CO, NC valve drain port

10-32 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

1. Locknut 7. Pin 13. Sleeve


2. Cover 8. Control piston 14. Guide spool
3. Plug 9. Locknut 15. Spring
4. Spring 10. Plug 16. Plug
5. Valve body 11. Locknut 17. Cover
6. Arm 12. Cover 18. Locknut

Function
Discharge amounts Q1 and Q2 of main pumps
PA1 and PA2 are controlled individually by the
respective servo valves. The relationship be-
tween pump discharge amount Q and input sig-
nal Pecn to the servo valve is as shown in the
graph on the right. Q varies in proportion to
Pecn.

PC750, 800-6 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 drain chamber e. As a result, servo piston
port a. chamber f is also interconnected with cham-
Signal pressure Pecn from the NC valve is ber e through port g and port d.
taken from port b to chamber c. At the same time, port a is interconnected
• When signal pressure Pecn rises, control pis- with port h, so the oil flows through port i to
ton (8) is pushed to the left by the hydraulic servo piston chamber j, pushes servo piston
pressure in chamber c, and stops at a point (19) to the left, increases the swash plate
where it balances the pressure of springs (4) angle in the main piston pump and increases
and (4A). the pump discharge amount.
At the same time, arm (6) uses servo piston • When servo piston (19) moves, arm (6) ro-
(19) as a fulcrum and sways to the left in the tates clockwise with its center at pin (7).
same way as control piston (8). This moves Guide spool (13) is moved to the right and
guide spool (13) to the left. closes port a, port d and port h, so the dis-
• When guide spool (13) moves, port a and charge increases by an amount that matches
port d are closed and port d is connected to signal pressure Pecn.

10-34 PC750, 800-6


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, con- At the same time, port a is interconnected
trol piston (8) moves to the right and stops with port d, so the oil flows through port g
at a point where the hydraulic pressure in to servo piston chamber f, pushes servo pis-
chamber c balances the pressure of springs ton (19) to the right, decreases the swash
(4) and (4A). plate angle in the main piston pump and
At the same time, arm (6) uses servo piston decreases the pump discharge amount.
(19) as a fulcrum and sways to the right in • When servo piston (19) moves, arm (6) ro-
the same way as control piston (8). This tates counterclockwise with its center at pin
moves guide spool (13) to the right. (7). Guide spool (13) is moved to the left and
• When guide spool (13) moves, port a and closes port a, port d and port h, so the dis-
port h are closed and port h is connected to charge decreases by an amount that matches
drain chamber e. As a result, servo piston signal pressure Pecn.
chamber j is also interconnected with cham-
ber e through port i and port h.

PC750, 800-6 10-35


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

5. TVC valve

Psv : Servo basic pressure IN port 1. Spring 5. Sleeve


PA1 : Main pump pressure IN port 2. Spool 6. Piston
PA2 : Main pump pressure IN port 3. Piston 7. Body
Pd : TVC valve drain OUT port 4. Piston 8. Solenoid
Pe : TVC valve output pressure OUT port

10-36 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

OPERATION AND FUNCTION OF TVC VALVE


1) When command current value from controller is small in DH and H mode

Function Operation
• When the power mode is at DH mode or H • The command current sent from the con-
mode, the pump discharge amount is con- troller actuates solenoid push pin (9) and
trolled to the optimum amount by the com- spool (2) moves. When this happens, the
mand current sent from the controller in ac- piston stops at a point where it balances the
cordance with the variation in the engine total of the force of spring (1), the force of
speed. push pin (9), and the force of
• In G mode or when the pump prolix switch TVC output pressure Pe acting on piston (3).
is ON, the pump discharge amount is con- The command current at this point is small,
trolled according to the pump discharge pres- so spool (2) is balanced at the bottom.
sure (load) by hydraulic sensing which fol- As a result, port a and port b are almost
lows a constant pump absorption torque. completely open, so the pressure oil from
the control pump is almost all output as TVC
fl For details, see MACHINE CONTROL SYS- output pressure Pe.
TEM. In this way, the pump discharge amount be-
comes the maximum.

PC750, 800-6 10-37


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

2) When command current value from controller is large in DH and H mode

Operation
• The command current sent from the con-
troller 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 de-
creases.

10-38 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

3) When pump load is small in G mode (pump prolix switch ON)

• When G mode is selected (pump prolix • Main pump discharge pressures PA1 and
switch ON) solenoid push pin (9) is pushed PA2 are low, so spool (2) is pushed down
up, increases the set pressure of spring (1), fully by spring (1). As a result, control pump
and this condition is maintained. discharge pressure Psv and TVC valve out-
• As a result, the pump absorption torque be- put pressure Pe are equal.
comes constant, so TVC output pressure Pe At this point, TVC valve output pressure Pe
(= pump discharge amount) is controlled by becomes the maximum, and the main pump
the pump discharge pressure. discharge amount is also the maximum.

PC750, 800-6 10-39


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

4) When pump load is large in G mode (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, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

6. No. 1 pump front CO, NC valve

10-42 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

CO valve NC valve
1. Plug 7. Plug
2. Piston 8. Sleeve
3. Spring 9. Piston
4. Spool 10. Spool
5. Piston 11. Spring
6. Plug 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
Pt : Jet sensor upstream pressure IN port
Pdr2 : CO, NC valve drain OUT port
Pecn : CO, NC valve output pressure OUT port

PC750, 800-6 10-43


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

7. No. 1 pump rear CO, NC valve

10-44 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

CO valve NC valve
1. Plug 7. Plug
2. Piston 8. Sleeve
3. Spring 9. Piston
4. Spool 10. Spool
5. Piston 11. Spring
6. Plug 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 in-
terconnection port
Pe2 : TVC valve output pressure IN port
Pc : CO selector pilot port
Pd : Jet sensor downstream pressure IN port
Pt : Jet sensor upstream pressure IN port
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, 800-6 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 Operation
• When the load becomes large during opera- • Spool (4) is being pushed down fully by
tions and the main pump discharge pres- spring (3).
sure rises to a point close to relief pressure, As a result, port a and port b are fully open
the cut-off function of the CO valve acts to and TVC valve output pressure Pe and CO
reduce the pump discharge in order to re- valve output pressure Pec are equal.
duce relief loss. In this way, CO valve output pressure Pec
• At the same time, it has a cut-off cancel becomes the maximum and the main pump
function actuated by the pilot pressure from discharge amount also becomes the maxi-
the heavy-lift solenoid valve. mum.
• 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 PC750, 800-6


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 dis-


charge 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, 800-6 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, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

FUNCTION AND OPERATION OF NC VALVE


1) When control valve is at neutral

Function Operation
• The NC valve controls the main pump dis- • Jet sensor differential pressure (Pt – Pd) be-
charge amount according to the amount that comes the maximum, and the force of jet
the control valve spool is operated. This flow sensor output pressure Pt pushing piston
control function reduces the neutral loss and (10) becomes larger than the total of the
fine control loss. force of spring (12) and the force of jet sen-
• The NC valve is controlled by balancing the sor output pressure Pd pushing the bottom
total of the jet sensor output pressure Pt of spool (11).
and the NC valve output pressure Pecn with As a result, spool (11) is pushed down, so
the total of the force of NC valve spring (12) the flow to port c and port b is throttled, and
and the jet sensor output pressure Pd. the area of the opening of port b and port a
• The jet sensor picks up the flow of oil re- (drain port) becomes larger. In this way, NC
turning to the tank through the control valve valve output pressure Pecn becomes the
and takes them as Pt and Pd of the NC valve. minimum, and the main pump discharge
amount also becomes the minimum.

PC750, 800-6 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 in-
creases according to the amount the control
lever is operated.

10-50 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

NO. 2 PUMP ASSEMBLY

HPV95 + 95

1. Front pump PA1 : Discharge port


2. Front servo valve PA2 : Discharge port
3. Rear servo valve Pd11 : Drain port
4. Rear pump Pd21 : Drain port
Ps : Suction port
Psv : Servo basic pressure IN port
Pecn : CO, NC valve output pressure IN port
P1 : Pilot pressure IN port

PC750, 800-6 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, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

1. Front shaft 8. Front end cap 15. Rear case


2. Front cradle 9. Coupling 16. Rocker cam
3. Front case 10. Impeller 17. Rear cradle
4. Rocker cam 11. Rear end cap 18. Rear shaft
5. Piston 12. Valve plate 19. Servo piston
6. Cylinder block 13. Cylinder block
7. Valve plate 14. Piston

PC750, 800-6 10-53


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

2. No. 2 pump front servo assembly

1. Servo valve PA1 : Main pump pressure IN port


PA2 : Main pump pressure IN port
Pac : Servo actuator port
Pdr : Servo valve drain OUT port
Psv : Servo basic pressure IN port
Pecn : CO, NC valve output pressure IN port

10-54 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

3. No. 2 pump rear servo assembly

1. Servo valveassembly PA2 : Main pump pressure IN port


Pac : Servo actuator port
Pav : Servo basic pressure IN port
Pecn :CO, NC valve output pressure detection
IN port
Pdr : Servo valve drain OUT port
P1 : Pilot pressure IN port

PC750, 800-6 10-55


LINE OIL FILTER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PILOT OIL FILTER

LINE OIL FILTER

1. Element
2. Body
3. Cover

PILOT OIL FILTER

1. Bracket
2. Cartridge
3. Element

10-56 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRAIN OIL FILTER

DRAIN OIL FILTER

1. Cartridge
2. Safety valve
3. Bracket

PC750, 800-6 10-57


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD L.H. 5-SPOOL CONTROL VALVE

L.H. 5-SPOOL CONTROL VALVE


P : From rear pump
T : To tank (Main drain)
A1 : To boom cylinder bottom
A2 : To swing motor port MA (Swing RIGHT)
A3 : To arm cylinder bottom
A4 : To bucket cylinder bottom
A5 : To travel motor (Left travel port P2)
B1 : Blind
B2 : To swing motor (Port MB)
B3 : To arm cylinder head
B4 : Blind (Standard machine)
B5 : To travel motor (Left travel port P1)
P1 : Valve (From straight travel valve port P2 of right 4-spool valve)
PP : From straight travel changeover solenoid valve
TC : Drain
PA1 : From PPC valve (Boom LOWER)
PA2 : From PPC valve (Swing LEFT)
PA3 : From PPC valve (Arm OUT)
PA4 : Standard; Bucket DUMP PPC valve or drain
Optional: Optional PPC valve (via shuttle valve)
PA5 : From PPC valve (Left travel FORWARD)
PB1 : From PPC valve (Boom RAISE)
PB2 : From PPC valve (Swing RIGHT)
PB3 : From PPC valve (Arm IN)
PB4 : From PPC valve (Bucket CURL)
PB5 : From PPC valve (Left travel REVERSE)
PC1 : From pilot valve (Port A2)
PC2 : From pilot valve (Port A1)
NCA : To pump (NC valve J/S upstream pressure)
NCB : To pump (NC valve J/S downstream pressure)

10-58 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD L.H. 5-SPOOL CONTROL VALVE

PC750, 800-6 10-59


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD L.H. 5-SPOOL CONTROL VALVE

1. Main relief valve 7. Spool return spring 13. Check valve


2. Spool (boom Hi) 8. Valve body 14. Suction-safety valve
3. Spool (swing) 9. Jet sensor orifice 15. Suction valve
4. Spool (arm Lo) 10. Jet sensor relief valve 16. Check valve with orifice
5. Spool (bucket Hi) 11. Throttle valve
6. Spool (L.H. travel) 12. Check valve spring

10-60 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD L.H. 5-SPOOL CONTROL VALVE

10-62 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD L.H. 5-SPOOL CONTROL VALVE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length Installation Installation Free Installation


1 Main relief valve, main valve spring × OD length load length load
394.2 N 315.2 N
34.7 × 10.1 32.5 {40.2 kg} — {32.2 kg}
Jet sensor relief valve, pilot poppet 30 N 24.3 N
2 spring 34.5 × 8.8 29.4 {3.1 kg} — {2.5 kg}
Jet sensor relief valve, main valve 49 N 39.2 N Replace
3 spring 37.4 × 11.4 33 {5.0 kg} — {4.0 kg} spring if
damaged
431 N 345 N or
4 Spool return spring 69.9 × 57 63 {44 kg} — {35.2 kg} deformed
0N 0N
5 Spool return spring 75 × 37 74.3 {0 kg} — {0 kg}
1N 0.78 N
6 Throttle valve spring 31.8 × 7.6 26.5 {0.1 kg} — {0.08 kg}
18.8 N 15.1 N
7 Check valve spring 78.2 × 26.6 52 {1.92 kg} — {1.54 kg}
18.8 N 15.1 N
8 Check valve spring (throttle valve) 65.3 × 14 46 {1.92 kg} — {1.54 kg}

PC750, 800-6 10-63


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD R.H. 4-SPOOL CONTROL VALVE

R.H. 4-SPOOL CONTROL VALVE


P : From front pump
T : To tank
A1 : To travel motor (Right travel port P1)
A2 : To boom cylinder head
A3 : To bucket cylinder bottom
A4 : To arm cylinder head
B1 : To travel motor (Right travel port P2)
B2 : To boom cylinder bottom
B3 : To bucket cylinder head
B4 : To arm cylinder bottom
P1 : From rear pump
P2 : To left 5-spool valve port P1
PP : From straight travel changeover solenoid valve
PR : From 2-stage main relief valve changeover solenoid valve
PS : From 2-stage safety valve changeover solenoid valve
PT : Drain
PA1 : From PPC valve (Right travel FORWARD)
PA2 : From PPC valve (Boom RAISE)
PA3 : From PPC valve (Bucket DUMP)
PA4 : From PPC valve (Arm IN)
PB1 : From PPC valve (Right travel REVERSE)
PB2 : From PPC valve (Boom LOWER)
PB3 : From PPC valve (Bucket CURL)
PB4 : From PPC valve (Arm OUT)
NCA : To pump (NC valve J/S upstream pressure)
NCB : To pump (NC valve J/S downstream pressure)

10-64 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD R.H. 4-SPOOL CONTROL VALVE

PC750, 800-6 10-65


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD R.H. 4-SPOOL CONTROL VALVE

1. Main relief valve 6. Spool return spring 11. Check valve spring
2. Spool (R.H. travel) 7. Valve body 12. Straight-travel valve
3. Spool (boom Lo) 8. Jet sensor orifice 13. Suction valve
4. Spool (bucket Lo) 9. Jet sensor relief valve 14. Suction-safety valve
5. Spool (arm Hi) 10. Check valve 15. Suction-safety valve

10-66 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD R.H. 4-SPOOL CONTROL VALVE

10-68 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD R.H. 4-SPOOL CONTROL VALVE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length Installation Installation Free Installation


1 Main relief valve, main valve spring × OD length load length load
394.2 N 315.2 N
34.7 × 10.1 32.5 {40.2 kg} — {32.2 kg}
Jet sensor relief valve, pilot poppet 30 N 24.3 N
2 spring 34.5 × 8.8 29.4 {3.1 kg} — {2.5 kg} Replace
spring if
Jet sensor relief valve, main valve 49 N 39.2 N damaged
3 spring 37.4 × 11.4 33 {5.0 kg} — {4.0 kg} or
431 N 345 N deformed
4 Spool return spring 69.9 × 57 63 {44 kg} — {35.2 kg}
0N 0N
5 Spool return spring 75 × 37 74.5 {0 kg} — {0 kg}
18.8 N 15.1 N
6 Check valve spring 78.2 × 26.6 52 {1.92 kg} — {1.54 kg}
18.8 N 15.1 N
7 Check valve spring 41.3 × 35.5 25.5 {1.92 kg} — {1.54 kg}

PC750, 800-6 10-69


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STRAIGHT-TRAVEL VALVE

STRAIGHT-TRAVEL VALVE

P : From pump (Front)


PP : From straight travel changeover solenoid valve
PT : Drain
P1 : From pump (Rear)
P2 : To left travel (Left 5-spool control valve)
P3 : To bucket and boom
P4 : To arm

10-70 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STRAIGHT-TRAVEL VALVE

1. Orifice
2. Check valve
3. Spring
4. Spool return spring
5. Body
6. Spool
7. Cover

PC750, 800-6 10-71


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 (straight-
travel solenoid valve de-energized)
• The straight-travel solenoid valve is de-en-
ergized, so no pilot pressure flows, and spool
(6) remains pushed to the left.
• Because of this, port P2 (left travel circuit)
and port P1 (right travel circuit) are not in-
terconnected, and each circuit remains inde-
pendent.

When travel and work equipment are operated


at same time (straight-travel solenoid valve ex-
cited)
• The straight-travel solenoid valve is excited,
so the pilot pressure flows and spool (6) is
pushed to the right.
• Because of this, port P2 and port P1 are
interconnected, so the amount of oil sup-
plied 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.

10-72 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR

SWING MOTOR
KMF125AB-5

B : From swing lock solenoid valve Specifications


S : From back pressure compensation valve Model : KMF125AB-5
T : To tank Theoretical displacement : 125.0 cm3/rev
MA : From control valve Safety valve set pressure : 27.9 MPa {285 kg/cm2}
MB : From control valve Rated revolving speed : 1,936 rpm
Brake release pressure : 1.9 MPa {19 kg/cm2}

PC750, 800-6 10-73


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR

1. Brake spring 7. Brake piston 13. Center spring


2. Drive shaft 8. Housing 14. Safety valve
3. Spacer 9. Piston 15. Check valve
4. Case 10. Cylinder block 16. Check valve spring
5. Disc 11. Valve plate 17. Shuttle valve
6. Plate 12. Center shaft 18. Shuttle valve spring

10-74 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length × Installed Installed Free Installed If damaged


1 Check valve spring Outside diameter length load length load or
deformed,
3.5 N 2.8 N replace
62.5 × 20.0 35 {0.36 kg} — {0.29 kg} spring
13.7 N 10.8 N
2 Shuttle valve spring 16.4 × 8.9 11.5 {1.4 kg} — {1.1 kg}

PC750, 800-6 10-75


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 pres-
sure oil is relieved to port S from the outlet
port of the motor (high-pressure side) to pre-
vent 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 sup-
plied to port MA. As a result, the pressure at
port MA rises, the starting torque is gener-
ated in the motor, and the motor starts to
rotate. The oil from the outlet port of the
motor passes from port MA thought the con-
trol 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 mo-
tor. (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.

10-76 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR

Operation of swing brake


1) When swing brake solenoid valve is de-en-
ergized
If the swing brake solenoid valve is de-ener-
gized, the flow of pressurized oil from the
control pump is shut off, and port B is con-
nected 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 en-
ergized, the valve is switched, and pressur-
ized oil from the control valve enters port B
and flows to brake chamber a.
The pressurized oil entering chamber a over-
comes 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, 800-6 10-77


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER SWIVEL JOINT

CENTER SWIVEL JOINT

1. Cover
2. Body
3. Slipper seal
4. Oil seal
5. Shaft
Unit: mm

No. Check item Criteria Remedy

Standard size Standard clearance Clearance limit


6 Clearance between rotor and shaft Replace
110 0.056 – 0.105 0.111

10-78 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR

TRAVEL MOTOR
MSF-340VP-EH

1. Travel selector valve Specifications


2. Motor Model : MSF-340VP-EH
3. Travel brake valve Theoretical delivery : 1st 337.2 cc/rev
: 2nd 212.6 cc/rev
Rated pressure : 31.4 MPa {320 kg/cm2}
P1 : From control valve Rated speed : 1st 1,423 rpm
P2 : From control valve (at 500 ¬/min.)
P1 : From travel speed solenoid valve : 2nd 2,258 rpm
T : To hydraulic tank (at 500 ¬/min.)
Brake release pressure : 1.8 MPa {18.4 kg/cm2}

PC750, 800-6 10-79


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
2. Relief valve
2a. Shockless piston
2b. Poppet

10-80 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR

3. Rear cover 10. Piston assembly 17. Plate


4. Collar 11. Case 18. Brake piston
5. Valve plate 12. Shaft 19. Spring
6. Cylinder block assembly 13. Bearing collar
7. Piston assembly 14. Rocker cam
8. Holder 15. Preload spring
9. Retainer 16. Disc

PC750, 800-6 10-81


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR

1-1 Motor

• There are 9 pistons (7) assembled in cylin-


der block (6). The end face of the cylinder
block has a spherical surface and is in con-
tact 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 (13) 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 se-
lector 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.

10-82 PC750, 800-6


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 (1a) and is drained into the motor case. There
pump is 0, spool (1a) of travel speed selec- is no angle propulsion force acting on rocker
tor valve (1) is not switched. cam (14), so the low-speed surface is kept in
In this condition, the oil from the chamber a static condition.
of control piston (10) passes through spool

PC750, 800-6 10-83


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR

2) At high speed (automatic 2nd)

• When the pilot signal is ON, pilot pressure When this happens, the main oil pres-
PI from the control pump acts on travel speed sure (M1, M2) passes through spool (1a)
selector valve (1) and the capacity is auto- and goes to the control piston chamber.
matically changed by the drive pressure of Rocker cam (14) overcomes moment Mx
the travel motor. with hydraulic force from propulsion
force Fc of control piston (10). It rotates
Balance of force for travel speed selector and holds the moment balance at the
valve high speed surface and is held in posi-
F1 [Force pushing spool (1a) to right (high- tion (Mx < Fc, L).
speed side)] = A (area of spool (1a) re- ii) When operating the steering or travel-
ceiving pressure) x PI ing uphill, if the motor drive pressure is
F2 [Force pushing spool (1a) to left (low- high, and it goes above the set pressure,
speed side)] = A (area of spool (1a) re- the condition becomes F1 < F2, and spool
ceiving pressure) x PH (motor drive pres- (1a) is pushed to the left.
sure) + force of spring (1b) When this happens, the main oil pres-
sure (M1, M2) passes through spool (1a)
i) When traveling on level ground, if the and is drained to the motor case. This
travel motor drive pressure is low, the creates the low-speed condition in the
condition becomes F1 > F2, and spool same way as when PI = 0.
(1a) is pushed to the right.

10-84 PC750, 800-6


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 re-
lease pressure employs a self-pressure re-
lease method using the travel motor drive
pressure through the oil passage in the coun-
terbalance 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 neu-
tral, and the oil in the cylinder chamber is
released to the tank through the counterbal-
ance 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 cir-
cuit 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 pres-
surized oil from the pump actuates the coun-
terbalance 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 re-
leased.

PC750, 800-6 10-85


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR

1-4 Relief valve

1. Shockless piston
2. Poppet
a. Poppet orifice
b. Relief housing orifice
c. 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 pres-
sure-receiving area than the pressure-receiv-
ing 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 move-
ment of shockless piston (1) is completed
(approx. 0.25 sec).

2) When movement of shockless piston is com-


pleted (2nd stage)
The pressure in the relief valve spring cham-
ber rises, the pressure on both sides of pop-
pet (2) becomes the same, and it becomes
the specified set pressure.

fl Set pressure and amount of adjustment


Amount of adjustment for one turn:
Approx. 7.8 MPa {80 kg/cm2}

10-86 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR

1-5 Travel brake valve

Function 1. Cap assembly


• The brake valve consists of counterbalance 2. Return spring
valve (3) and check valve (4). 3. Counterbalance valve
• The counterbalance valve acts to prevent the 4. Check valve
piston motor from stopping or overrunning. 5. Check valve spring
• When traveling downhill, the weight of the
machine makes it try to travel at a speed
faster than the rotation of the motor. Specification
For this reason, if the machine is traveling Safety valve set pressure: 34 MPa {350 kg/cm2}
with the engine running at low speed, the Counterbalance switching pressure:
motor will rotate under no load or may run 1.0 ± 0.1 MPa {10 ± 1 kg/cm2}
away, which is extremely dangerous. Check valve switching pressure:
To prevent this, this valve controls the 0.02 ± 0.01 MPa {0.2 ± 0.1 kg/cm2}
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 mo-
tor.

PC750, 800-6 10-87


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR

Operation when oil is supplied


• When the travel lever is operated, the pres-
surized oil from the control valve is supplied
to port P1. It pushes open check valve (5a)
and flows from motor inlet port M1 to mo-
tor outlet port M2.
However, the motor outlet port is closed by
check valve (5b) and spool (3), so the pres-
sure 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 con-
nected, 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 trav-
eling 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 be-
low 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 ro-
tation of the motor, and this prevents the
machine from running away.
In other words, spool (3) moves to a posi-
tion 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.

10-88 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC CONTROL RELIEF VALVE

PPC CONTROL RELIEF VALVE

1. Valve body
2. Check valve spring
3. Check valve Specifications
4. Relief valve Set pressure: 3.1 MPa{32+3 2
+0 kg/cm } (at 135 ¬/min)

A : From control pump F : To PPC valve


B : From PPC valve G : To servo valve
C : Pump drain H : To accumulator
D : Motor drain T : To tank
E : Pump drain
Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length Installation Installation Free Installation


5 Check valve spring Replace
× OD length load length load
70.6 N 5.65 N
56 × 21.4 37 — {0.58 kg}
{0.72 kg}

PC750, 800-6 10-89


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SAFETY LOCK VALVE

SAFETY LOCK VALVE

1. Lever
2. End cap
3. Ball
4. Seat
5. Body

Outline
• The safety lock valve is installed between
the PPC valve and the control relief valve in
the PPC circuit. If the work equipment safety
lever is set to the LOCK position, the safety
lock valve is interconnected with the work
equipment safety lever, so it is actuated. It
stops the oil in the PPC circuit and makes it
impossible to operate the work equipment.

10-90 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC ACCUMULATOR

PPC ACCUMULATOR

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. 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 cham-
ber 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.

PC750, 800-6 10-91


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE CONTROL

VALVE CONTROL

1. R.H. 4-spool control valve 10. Safety lock lever Lever positions
2. L.H. 5-spool control valve 11. Left PPC valve 1 HOLD
3. Accumulator 12. Left work equipment lever 2 Boom RAISE
4. No. 1 pump 13. Travel PPC valve 3 Boom LOWER
5. Control pump 14. L.H. travel lever 4 Bucket DUMP
6. No. 2 pump 15. R.H. travel lever 5 Bucket CURL
7. PPC control relief valve 16. Right PPC valve 6 HOLD
8. Shockless boom valve 17. Right work equipment lever 7 Arm IN
9. Safety lock valve 8 Arm OUT
9 Swing right
0 Swing left
A Neutral
B Travel REVERSE
C Travel FORWARD
D LOCK
E FREE

10-92 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT, SWING PPC VALVE

WORK EQUIPMENT, SWING PPC VALVE

P : From control pump P2 : Left: Swing left, Right: Bucket CURL


T : To hydraulic tank P3 : Left: Arm OUT, Right: Boom LOWER
P1 : Left: Swing right, Right: Bucket DUMP P4 : Left: Arm IN, Right: Boom RAISE

PC750, 800-6 10-93


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT, SWING PPC VALVE

1. Spool 6. Nut (for connecting lever)


2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Piston 9. Retainer
5. Disc 10. Body

10-94 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT, SWING PPC VALVE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length Installation Installation Free Installation


11 Centering spring (for P3, P4) × OD length load length load Replace
spring if
17.6 N 13.7 N
42.48 × 15.5 34 — {1.4 kg}
damaged
{1.8 kg} or
16.6 N 13.2 N deformed
12 Metering spring 26.7 × 8.14 24.9 — {1.35 kg}
{1.69 kg}
9.8 N 7.8 N
13 Centering spring (for P1, P2) 38.71 × 15.5 34 {1 kg} — {0.8 kg}

PC750, 800-6 10-95


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 con-
nected to drain chamber D at the bottom.
(Fig. 1)

2) Fine control (neutral → 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. Fine control hole f is shut
off from pump pressure chamber PP. At al-
most the same time, it is connected to drain
chamber D, so the pressure at port P1 es-
capes.
As a result, spool (1) moves up and down
until the force of metering spool (2) is bal-
anced 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 le-
ver, 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. (Fig. 2)

10-96 PC750, 800-6


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 cham-
ber D. At almost the same time, it is con-
nected 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. (Fig. 3)

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. (Fig.
4)

PC750, 800-6 10-97


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE

TRAVEL PPC VALVE

P : From control pump P1 : L.H. travel REVERSE


T : To hydraulic tank P2 : L.H. travel FORWARD
P3 : R.H. travel REVERSE
R4 : R.H. travel FORWARD

10-98 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE

1. Spool 5. Piston
2. Centering spring 6. Plate
3. Metering spring 7. Collar
4. Disc 8. Body

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length Installation Installation Free Installation Replace


9 Metering spring × OD length load length load spring if
damaged
16.6 N 13.2 N or
26.7 × 8.14 24.9 {1.69 kg} — {1.35 kg} deformed
108 N 86.2 N
10 Centering spring 48.1 × 15.5 32.5 {11 kg} — {8.8 kg}

PC750, 800-6 10-99


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 D
drain chamber D through fine control hole f
in spool (1). (Fig. 1)
f
T
P

P1 P2

A Control valve B

(Fig. 1)

SBP00281

2) Fine control (neutral → 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. 5
When this happens, fine control hole f is 4
shut off from drain chamber D. At almost D
9
the same time, it is connected to pump pres-
sure chamber PP, and the pilot pressure of 2
the control pump is sent from port A through f T
fine control hole f to port P1.
When the pressure at port P1 rises, spool (1) P
is pushed back. Fine control hole f is shut
off from pump pressure chamber PP. At al- 1
most the same time, it is connected to drain PP
chamber D, so the pressure at port P1 es- P1 P2
10
capes.
As a result, spool (1) moves up and down
A Control valve B
until the force of metering spool (2) is bal-
anced with the pressure of port P1. (Fig. 2)
The relationship of the positions of spool (1)
and body (10) (fine control hole f is in the SBP00282
middle between drain hole D and pump pres-
sure chamber PP) does not change until re-
tainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed
in proportion to the travel of the control le-
ver, 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. (Fig. 2)

10-100 PC750, 800-6


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. 5
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressur-
ized oil at port P1 is released. 3 D
If the pressure at port P1 drops too much, 2
spool (1) is pushed down by metering spring
(2), so fine control hole f is shut off from f T
drain chamber D. At almost the same time, P
it is connected to pump pressure chamber f'
PP, so the pressure at port P1 supplies the
1
pump pressure until the pressure recovers
PP
to a pressure equivalent to the position of
P1 P2
the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole f’ A B
Control valve
of the valve on the side that is not moving.
It passes through port P2 and goes to cham- (Fig. 3)
ber B to charge the oil. (Fig. 3)
SBP00283

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 5
connected to pump pressure chamber PP.
4
Therefore, the pilot pressure oil from the D
control pump passes through fine control 9
hole f and flows to chamber A from port P1
to push the control valve spool. f T
The return oil from chamber B passes from
port P2 through fine control hole f’ and flows P
f'
to drain chamber D. (Fig. 4)
1
PP
P1 P2

A Control valve B

(Fig. 4)

SBP00284

PC750, 800-6 10-101


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. CO resetting solenoid valve T : To tank


2. Straight travel solenoid valve A1 : To No. 1 pump (CO valve)
3. Heavy lift solenoid valve A2 : To straight travel valve
4. Machine push-up solenoid valve A3 : To main valve (Relief valve)
5. Travel speed solenoid valve A4 : To boom LOWER 2-stage safety valve
A5 : To left and right travel motor
P1 : From control pump
ACC : Blind
PPC : Blind

10-102 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE

FOR SWING HOLDING BRAKE (ON RIGHT SIDE OF MACHINE BODY)

1. Swing holding brake solenoid valve

T : To tank
A : To front and rear swing motors
P : From control pump

PC750, 800-6 10-103


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE

1. Connector
2. Movable core
3. Coil
4. Cage
5. Spool
6. Block
7. 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 con-
trol 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.

10-104 PC750, 800-6


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

PC750, 800-6 10-105


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE

1. Connector
2. Movable iron core
3. Coil
4. Spool
5. Body
6. Spring
7. 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 con-
troller 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 pres-
sure 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.

10-106 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

HYDRAULIC CYLINDER
BACKHOE SPECIFICATION
PC750, 750LC, 800-6 STD

BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-108 PC750, 800-6


(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

Unit: mm

No. Check item Criteria Remedy

Tolerance
Name of Standard Standard Clearance
scylinder size clearance limit
Shaft Hole
Clearance between
–0.043 +0.256 0.082 – Replace
1 piston rod and Boom 140 0.062
–0.106 +0.039 0.362 bushing
bushing
–0.043 +0.256 0.082 –
Arm 140 0.062
–0.106 +0.039 0.362
–0.036 +0.263 0.084 –
Bucket 120 0.062
–0.090 +0.048 0.353
–0.036 +0.025 0.036 –
Boom 115 1.5
–0.090 +0 0.115
Clearance between –0.036 +0.025 0.036 –
2 piston rod support Arm 115 –0.090 +0 0.115 1.5
shaft and bushing
–0.036 +0.457 0.406 –
Bucket 110 1.5 Replace
–0.090 +0.370 0.547
pin,
–0.043 +0.025 0.043 – bushing
Boom 130 –0.106 +0 0.131 1.5
Clearance between
cylinder bottom –0.043 +0.025 0.043 –
3 Arm 130 –0.106 +0 0.131 1.5
support shaft and
bushing
–0.036 +0.457 0.406 –
Bucket 110 1.5
–0.090 +0.370 0.547

PC750, 800-6 10-109


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

PC750SE, 800SE-6
BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-110 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

Unit: mm

No. Check item Criteria Remedy

Tolerance
Name of Standard Standard Clearance
scylinder size clearance limit
Shaft Hole
Clearance between
–0.043 +0.263 0.084 – Replace
1 piston rod and Boom 140 0.062
–0.106 +0.048 0.353 bushing
bushing
–0.036 +0.256 0.082 –
Arm 120 0.062
–0.090 +0.039 0.362
–0.043 +0.256 0.082 –
Bucket 160 0.062
–0.106 +0.039 0.362
–0.036 +0.025 0.036 –
Boom 115 1.5
–0.090 +0 0.115
Clearance between –0.036 +0.457 0.406 –
2 piston rod support Arm 110 –0.090 +0.370 0.547 1.5
shaft and bushing
–0.043 +0.025 0.043 –
Bucket 140 1.5 Replace
–0.106 +0 0.131
pin,
–0.043 +0.025 0.043 – bushing
Boom 130 –0.106 +0 0.131 1.5
Clearance between
cylinder bottom –0.036 +0.457 0.406 –
3 Arm 110 –0.090 +0.370 0.547 1.5
support shaft and
bushing
–0.043 +0.025 0.043 –
Bucket 140 1.5
–0.106 +0 0.131

PC750, 800-6 10-111


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

LOADING SHOVEL SPECIFICATION (with bucket link)


PC750-6

BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-111-1 PC750, 800-6


(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

BOTTOM DUMP CYLINDER

Unit: mm

No. Check item Criteria Remedy

Tolerance
Name of Standard Standard Clearance
scylinder size clearance limit
Shaft Hole

–0.043 +0.256 0.082 –


Clearance between Boom 140 –0.106 +0.039 0.362 0.662
1 piston rod and
bushing –0.043 +0.256 0.082 – Replace
Arm 160 –0.106 +0.039 0.362 0.662 bushing
–0.043 +0.256 0.083 –
Bucket 130 –0.106 +0.040 0.362 0.662

–0.036 +0.257 0.084 –


Bottom dump 90 –0.090 +0.048 0.347 0.647

–0.036 +0.025 0.036 –


Boom 115 –0.090 +0 0.115 1.5

–0.043 +0.025 0.043 –


Clearance between Arm 140 –0.106 +0 0.131 1.5
2 piston rod support
shaft and bushing –0.036 0 0.016 –
Bucket 115 –0.090 +–0.020 0.090 1.5

–0.036 +0.457 0.406 –


Bottom dump 90 –0.090 +0.370 0.547 1.5 Replace
pin,
–0.043 +0.025 0.043 – bushing
Boom 130 –0.106 +0 0.131 1.5

Clearance between –0.043 +0.025 0.043 –


Arm 140 –0.106 +0 0.131 1.5
3 cylinder bottom
support shaft and –0.036 0 0.016 –
bushing Bucket 115 –0.090 +–0.020 0.090 1.5

–0.036 +0.457 0.406 –


Bottom dump 90 –0.090 +0.370 0.547 1.5

PC750, 800-6 10-111-2


(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

LOADING SHOVEL SPECIFICATION (without bucket link)


PC750-6

BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-111-3 PC750, 800-6


(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

BOTTOM DUMP CYLINDER

Unit: mm

No. Check item Criteria Remedy

Tolerance
Name of Standard Standard Clearance
scylinder size clearance limit
Shaft Hole

–0.043 +0.256 0.082 –


Clearance between Boom 140 –0.106 +0.039 0.362 0.662
1 piston rod and
bushing –0.043 +0.256 0.082 – Replace
Arm 160 –0.106 +0.039 0.362 0.662 bushing
–0.043 +0.256 0.083 –
Bucket 130 –0.106 +0.040 0.362 0.662

–0.036 +0.257 0.084 –


Bottom dump 90 –0.090 +0.048 0.347 0.647

–0.036 +0.025 0.036 –


Boom 115 –0.090 +0 0.115 1.5

–0.043 +0.025 0.043 –


Clearance between Arm 140 –0.106 +0 0.131 1.5
2 piston rod support
shaft and bushing –0.036 0 0.016 –
Bucket 115 –0.090 +–0.020 0.090 1.5

–0.036 +0.457 0.406 –


Bottom dump 90 –0.090 +0.370 0.547 1.5 Replace
pin,
–0.043 +0.025 0.043 – bushing
Boom 130 –0.106 +0 0.131 1.5

Clearance between –0.043 +0.025 0.043 –


Arm 140 –0.106 +0 0.131 1.5
3 cylinder bottom
support shaft and –0.036 0 0.016 –
bushing Bucket 115 –0.090 +–0.020 0.090 1.5

–0.036 +0.457 0.406 –


Bottom dump 90 –0.090 +0.370 0.547 1.5

PC750, 800-6 10-111-4


(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

WORK EQUIPMENT
BACKHOE SPECIFICATION
PC750-6
PC750LC-6

10-112 PC750, 800-6


(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between bushing and size clearance limit
1 mounting pin of boom and Shaft Hole
revolving frame
–0.043 +0.542 0.485 –
140 –0.106 +0.442 0.648 1.5

Clearance between bushing and –0.043 +0.542 0.485 –


2 mounting pin of boom and arm 140 –0.106 +0.442 0.648 1.5
Replace
Clearance between bushing and –0.036 +0.351 0.307 –
3 mounting pin of arm and link 115 –0.090 +0.271 0.441 1.5

Clearance between bushing and –0.043 +0.482 0.435 –


4 mounting pin of arm and bucket 130 –0.106 +0.392 0.588 1.5

Clearance between bushing and –0.036 +0.351 0.307 –


5 mounting pin of link and link 110 –0.090 +0.271 0.441 1.5

Clearance between bushing and –0.036 +0.351 0.307 –


6 mounting pin of link and bucket 115 –0.090 +0.271 0.441 1.5

Adjust
7 Bucket clearance 0.5 – 1.0 shims

PC750, 800-6 10-113


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

PC750SE-6
PC800, 800SE-6

10-114 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between bushing and size clearance limit
1 mounting pin of boom and Shaft Hole
revolving frame
–0.043 +0.542 0.485 –
140 –0.106 +0.442 0.648 1.5

Clearance between bushing and –0.043 +0.542 0.485 –


2 mounting pin of boom and arm 140 1.5
–0.106 +0.442 0.648
Clearance between bushing and –0.036 +0.351 0.307 – Replace
3 mounting pin of arm and link 115 1.5
–0.090 +0.271 0.441
Clearance between bushing and –0.043 +0.482 0.435 –
4 mounting pin of arm and bucket 130 1.5
–0.106 +0.392 0.588
–0.036 +0.351 0.307 –
Clearance between PC800 110 –0.090 +0.271 0.441 1.5
5 bushing and mounting
pin of link and link PC750SE –0.043 +0.397 0.313 –
140 1.5
PC800SE –0.106 +0.312 0.467

Clearance between bushing and –0.036 +0.351 0.307 –


6 115 1.5
mounting pin of link and bucket –0.090 +0.271 0.441
Adjust
7 Bucket clearance 0.5 – 1.0
shims

PC750, 800-6 10-115


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

LOADING SHOVEL SPECIFICATION (with bucket link)


PC750-6

10-115-1 PC750, 800-6


(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between boom-revolving size clearance limit
1 frame mounting pin and bushing Shaft Hole

–0.043 +0.424 0.363 –


140 –0.106 +0.320 0.530 1.5

Clearance between boom-arm –0.043 +0.100 0.043 –


2 mounting pin and bushing 140 1.5
–0.106 0 0.206
Clearance between arm-link –0.036 +0.351 0.307 –
3 mounting pin and bushing 115 1.5 Replace
–0.090 +0.271 0.441
Clearance between arm-bucket –0.043 +0.351 0.314 –
4 mounting pin and bushing 140 1.5
–0.106 +0.271 0.475
Clearance between link-link –0.036 +0.351 0.307 –
5 mounting pin and bushing 115 –0.090 +0.271 0.441 1.5

Clearance between link-bucket –0.036 +0.351 0.307 –


6 mounting pin and bushing 115 1.5
–0.090 +0.271 0.441
Clearance between front bucket- –0.036 +0.344 0.308 –
7 rear bucket mounting pin and bushing 95 1.5
–0.090 0 0.434

PC750, 800-6 10-115-2


(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

LOADING SHOVEL SPECIFICATION (without bucket link)


PC750-6

10-115-3 PC750, 800-6


(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between boom-revolving size clearance limit
1 frame mounting pin and bushing Shaft Hole

–0.043 +0.542 0.485 –


140 –0.106 +0.442 0.648 1.5

Clearance between boom-arm –0.043 +0.542 0.485 –


2 mounting pin and bushing 140 1.5 Replace
–0.106 +0.442 0.648
Clearance between arm-bucket –0.043 +0.523 0.503 –
3 mounting pin and bushing 140 1.5
–0.106 +0.460 0.629
Clearance between bucket cylinder- –0.036 +0.457 0.406 –
4 bucket mounting pin and bushing 115 –0.090 +0.370 0.547 1.5

Clearance between front bucket- –0.036 +0.344 0.308 –


5 rear bucket mounting pin and bushing 95 –0.090 0 0.434 1.5

PC750, 800-6 10-115-4


(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT

DIMENSIONS OF WORK EQUIPMENT


1. ARM

10-116 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT

Unit: mm
PC750SE-6
Model PC750-6 PC800-6
PC800SE-6
with 3.6 m with 4.6 m with 5.6 m with 3.6 m with 2.9 m
No. arm arm arm heavy-duty arm short arm

1 115 115 115 110 110

2 100 100 100 129 129

3 531 531 531 531 531

4 140 140 140 140 140

5 580 619.5 638.8 663 750.2

6 397 466.8 530 328.6 401.4

7 1,331.5 1,389 1,328 925.4 915.9

8 3,577.5 4,569.4 5,574.5 3,584.5 2,917.3

9 3,675 3,687.7 3,673 4,011.4 3,579.8

10 585 570 585 585 500

11 950 950 950 950 840

12 740 740 740 740 740

13 756 756 756 756 756

14 2,237 2,237 2,237 2,237 2,237

15 115 115 115 115 115

16 519 519 519 519 519

17 130 130 130 130 130

Arm as individual
part 519 519 519 519 519
18
When pressfitting
bushing 535 535 535 535 535

Min. 2,380 2,380 2,380 2,590 2,490


19
Max. 3,990 3,990 3,990 4,410 3,910

PC750, 800-6 10-117


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT

2. BUCKET

10-118 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT

Unit: mm

Model PC750SE-6
PC750-6 PC800-6
PC800SE-6
with 2.8 m3 with 3.1 m3 with 3.4 m3 with 4.0 m3 with 4.3 m3 with 4.5 m3
No. bucket bucket bucket bucket bucket bucket

1 748.8 748.8 747.1 667 667 667

2 104 104 164.3 61 61 61

3 98°C 98°C 102.4°C 95°C 95°C 95°C

4 756 756 765 670 670 670

5 2,218 2,218 2,218 2,211 2,211 2,211

6 291.6 291.6 291.6 314.6 314.6 314.6

a ø130 ø130 ø130 ø130 ø130 ø130


7
b ø115 ø115 ø115 ø115 ø115 ø115

8 520 520 520 520 520 520

9 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

11 ø208 ø208 ø238 ø208 ø208 ø208

12 ø255 ø255 ø255 ø255 ø255 ø255

13 ø275 ø275 ø275 ø275 ø275 ø275

14 217 217 253 135 135 135

15 175 175 175 181 181 181

16 157.5 157.5 157.5 157.5 157.5 157.5

17 125 125 140 125 125 125

18 559.5 559.5 559.5 559.5 559.5 559.5

19 79 79 79 79 79 79

PC750, 800-6 10-119


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER

AIR CONDITIONER
AIR CONDITIONER PIPING
STD CAB SPECIFICATION

1. Duct A. Fresh air


2. Condenser B. Recirculated air
3. Air conditioner compressor C. Hot air/cold air
4. Hot water return piping
5. Hot water pickup piping
6. Refrigerant piping
7. Receiver tank
8. Air conditioner unit

10-120 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL

ENGINE CONTROL

1. Battery Function
2. Battery relay • The engine can be started and stopped sim-
3. Starting switch ply by using starting switch (3).
4. Fuel control dial • A dial-type engine control is used to control
5. Supply pump the engine speed. Engine controller (7) re-
6. Starting motor ceives the control signal from fuel control
7. Engine controller dial (4), sends a drive signal to governor
motor (5), and controls the angle of the gov-
ernor lever in the fuel injection pump.

PC750, 800-6 10-121


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 throttle and
pump 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 a signal to the
engine throttle and pump controller accord-
ing to the position of the dial.
The engine throttle and pump controller cal-
culates the angle of the governor motor ac-
cording to this signal, and sends a signal to
drive the governor motor so that it is at that
angle.
When this happens, the operating angle of
the governor motor is detected by the po-
tentiometer, and feedback is sent to the en-
gine throttle and pump controller, so that it
can observe the operation of the governor
motor.

Stopping engine
• When the engine throttle, pump controller
detects that the starting switch is at the STOP
position, it cuts the signal to the fuel shut-
off solenoid, and stops the supply of fuel to
the engine to stop the engine.
• When this happens, the engine throttle,
pump controller itself drives the battery re-
lay to ensure that there is electricity inside
the system until the engine stops completely.

10-122 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL

2. Components of system
Fuel control dial

1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector

Function
• The fuel control dial is installed at the bot-
tom 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 throttle and pump con-
troller.
• The hatched area in the graph on the right is
the abnormality detection area and the en-
gine speed is set at low idling.

PC750, 800-6 10-123


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL

Engine controller

10-124 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL

Input and output signals


CN1 CN3 CN5
Pin Name of signal Input/ Pin Name of signal Input/ Pin Name of signal Input/
No. output No. output No. output
1 Common rail press. sensor Input 1 NC Output 1 GND
2 Accel sensor (Test mode) Input 2 ROM write enable switch Input 2 GND
3 Boost press. sensor Input 3 RS-232C TX1 Output 3 GND
4 Sensor power supply 1 Output 4 ROM write switch Input 4 Q monitor (Test mode) Output
5 Ne sensor (+) Input 5 NC Input 5 Power mode select 1 (Test mode) Input
6 Fuel dial Input 6 NC 6 Power mode select 2 (Test mode) Input
7 NC Input 7 RS-232C RX1 Input 7 Auto decel flag (Test mode) Input
8 NC Input 8 GND 8 Auto decel control (Test mode) Input
9 NC Input 9 GND
CN4
10 NC Input Pin Input/ 10 GND
Name of signal
11 Sensor GND No. output 11 GND
12 Ne sensor (–) Input 1 GND 12 Engine speed pulse (Test mode) Output
2 Starter switch (C) Input 13 Lever neutral flag (Test mode) Input
CN2
3 NC Input 14 Signal input 19 (Test mode) Input
Pin Name of signal Input/
No. output 4 Memory clear switch Input 15 Signal input 20 (Test mode) Input
1 G sensor (+) Input 5 Oil press switch (Low) Input 16 Signal input 21 (Test mode) Input
2 Sensor power supply 2 Output 6 Oil press switch (High) Input
CN6
3 Coolant temp. sensor (Low temp.) Input 7 Key switch (Acc) Input
Pin Name of signal Input/
4 Coolant temp. sensor (High temp.) Input 8 GND (Battery earth) Input No. output
5 NC Output 9 Power supply 1 NC Input
6 GND 10 GND 2 NC Output
Input, 11 Auto decel signal Input 3 Injector 3 (+) Output
7 NC
output 4 Injector 2 (+) Output
12 NC Input
Input,
8 S-NET (+) 13 Machine select 1 Input 5 NC Input
output
14 Machine select 2 Input 6 NC Output
9 G sensor (–) Input
15 Machine select 3 Input 7 Injector 1 (+) Output
10 Sensor GND
16 NC Input 8 Injector 1 (–) Output
11 Fuel temp. sensor Input
17 NC Input 9 Injector 3 (–) Output
12 NC Input
18 Key switch (Acc) Input 10 Injector 2 (–) Output
13 NC Output
19 GND (Battery earth) CN7
14 NC Output
20 Power supply Pin Input/
15 NC Output Name of signal
No. output
16 NC
1 Injector 5 (+) Output
Input,
17 NC 2 Injector 6 (+) Output
output
3 Injector 4 (+) Output
Input,
18 S-NET (+) 4 Supply pump 2 (+) Output
output
5 GND (Battery earth)
6 Power supply (Injector, supply pump)
7 Injector 5 (–) Output
8 Injector 6 (–) Output
9 Injector 4 (–) Output
10 Supply pump 1 (+) Output
11 Supply pump 1 (–) Output
12 Supply pump 2 (–) Output
13 GND (Battery earth)
14 Power supply (Injector, supply pump)

PC750, 800-6 10-125


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

MACHINE CONTROL SYSTEM


CONTROL FUNCTIONS

1 OFF (Cancel)
Auto deceleration function
ON
2 3-mode selector type pump torque control
Electronic OLSS function Cut-off control
Flow control
3 OFF
Heavy-lift function
ON
4 ON (Digging improvement mode)
2-stage boom pushing force
selector function
OFF (Machine push-up mode)
(Machine push-up)

5
Swing control function

6
Machine control Engine automatic warming up,
system overheat prevention function
Turboprotection function
Split injection function

7 Lo (Low speed) fixed


Travel speed selector
function Hi (High speed) →
← Lo (low speed)
automatic gear shift
8 ON
Boom shockless control
function
Cancel
9
Straight-travel function

10
Swing priority function

11
Boom assurance function

10-126 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

MACHINE CONTROL SYSTEM DIAGRAM

PC750, 800-6 10-127


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 consump-
tion and noise.
• If any lever is operated, the engine speed
returns immediately to the set speed.

10-128 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

Operation

1. When auto-deceleration switch is turned ON

Control levers at neutral When control lever is operated


• If the engine is running at above the decel- • If any control lever is operated when the
eration actuation speed (approx. 1400 rpm), engine speed is at No. 2 deceleration, the
and all the control levers are returned to engine speed will immediately rise to the
neutral, the engine speed drops immediately speed set by the fuel control dial.
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.

2. When auto-deceleration switch is turned OFF

Control lever at neutral When control lever is operated


• If the engine is running at a speed above • If any control lever is operated under the
1,880 rpm and all the control levers are re- condition shown at left (after the engine
turned to neutral, the engine speed drops to speed drops to approx. 1,880 rpm), the en-
approx. 1,880 rpm after 4 seconds and is gine speed will immediately rise to the speed
kept at that speed until a lever is operated. set by the fuel control dial.

PC750, 800-6 10-129


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

2. Electronic OLSS function


Pump control system

• Interconnected control of all pumps is car-


ried out by one TVC valve.
• DH mode: Total horsepower control by en-
gine speed sensing
H mode: Total horsepower control by en-
gine speed sensing
G Mode: Constant torque control
• Emergency pump drive circuit:
Absorption torque equivalent to G mode

10-130 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

1) Control method in each mode


DH, H mode

• Matching point in DH, H mode: Rated output


point
Model PC750-6
Mode PC800-6
DH 338 kW/1,800 rpm {454 HP/1,800 rpm}
H 309 kW/1,730 rpm {414 HP/1,730 rpm}

• When the load on the pump rises and the


pressure rises, the engine speed goes down.
When this happens, the pump discharge
amount is reduced, and the engine speed is
controlled so that it becomes close to the
rated speed.
If the reverse happens and the pressure goes
down, the system is controlled so that the
pump discharge amount is increased until
the engine speed reaches close to the rated
speed.
By repeating this control, the engine can al-
ways be used at near the rated output point.
• Compared with the DH mode, which pro-
vides the maximum output, the H mode low-
ers the engine output to provide matching
at a point which gives better fuel consump-
tion efficiency than the DH mode.
• The DH mode uses the CO cancel so it can
generate a greater discharge of oil than in
the H mode at high pressure.

PC750, 800-6 10-131


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

G mode

• Matching point

Mode G Model PC750-6


Mode PC800-6
Partial output point 78% 305 kW/1,750 rpm
G {409 HP/1,750 rpm}

• When the pump load increases and the pres-


sure rises, the engine speed drops.
When this happens, combined control of the
engine and pump carries out controls so that
the engine speed goes down while the pump
absorption torque is maintained constant
along the equal horsepower curve of the
engine.
• Compared with the H mode, the high idling
engine speed is lowered, so the engine can
be used in a good fuel consumption range.

2) Cut-off function
• If the load during operation increases and
the pump discharge pressure rises to near
the relief pressure, the main pump cut-off
valve is actuated to reduce the relief loss.

10-132 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

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 Working mode switch Swing lock switch Heavy lift

Function DH H G ON OFF ON OFF

Cut-off function Cancel Actuated Actuated Cancel Actuated Cancel Actuated

PC750, 800-6 10-133


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 au-
tomatically canceled.

10-134 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

Operation
Lever operation
Heavy-list Heavy-lift Main relief Boom
CO valve
switch Boom Arm IN or solenoid valve set lifting
switch
RAISE bucket CURL valve pressure force
De- 31.4 MPa
OFF Operated — Actuated Normal
energized {320 kg/cm2}
34.3 MPa Can-
Neutral Excited {350 kg/cm2} celed 10% up
ON Operated
If the arm IN or bucket CURL are operated dur-
Operated ing boom RAISE operations, this function is au- Normal
tomatically canceled, and the condition becomes
the same as when the switch is turned OFF.

fl Heavy-lift solenoid valve


For details of the structure and function, see SOLENOID VALVE ASSEMBLY.
fl CO valve
For details of the structure and function, see NO. 1 PUMP.
fl Main relief valve
For details of the structure and function, see L.H. 5-SPOOL VALVE.

PC750, 800-6 10-135


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 in-
creased digging efficiency by reducing the
digging resistance of the boom, and in-
creased ease of operation by increasing the
thrusting force for excavation, digging square
holes, carrying out twist turns, or escaping
from soft ground.

10-136 PC750, 800-6


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}.

Machine Machine
Mode Safety valve Effect
push-up push-up
set pressure
switch solenoid valve

By reducing the boom pushing force, it is


Boom made easier for the boom to escape auto-
pushing 14.7 MPa
Excited matically in the RAISE direction and to re-
force (low {150 kg/cm2} duce the number of times that the boom is
mode) operated. At the same time it also makes
the digging operation smoother.

Boom By increasing the thrust force for boom


33.3 MPa LOWER, the ease of operation is improved
pushing De-energized for excavation, digging square holes, carry-
force (high {340 kg/cm2} ing out twist turns, or escaping from soft
mode) ground.

fl Machine push-up solenoid valve


For details of the structure and function, see SOLENOID VALVE ASSEMBLY.
fl Boom safety valve
For details of the structure and function, see R.H. 4-SPOOL VALVE.

PC750, 800-6 10-137


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.

10-138 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

Swing lock, swing holding brake function


• The swing lock (manual) can be locked at fl Swing brake solenoid valve
any desired position, and the swing lock and For details of the structure and function, see
swing holding brake (automatic) are inter- SOLENOID ASSEMBLY.
connected with the swing, so they prevent fl Swing motor
any hydraulic drift after the swing is stopped. For details of the structure and function, see
SWING MOTOR.
Actuation
Swing lock Swing lock Swing brake
Mode switch lamp 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 See diagram


holding OFF OFF on right
brake

Swing lock is actuated and swing is held in position.


Swing
ON ON De-energized Even when swing lever is operated, swing lock is not
brake canceled and swing does not move.

Operation of swing lock prolix switch


• If any abnormality should occur in the con-
Swing
troller, and the swing holding brake is not lock
ON OFF
(when controller (when controller
actuated normally and the swing cannot be prolix is abnormal) is normal)
operated, the swing lock prolix switch can switch
be operated to cancel the swing lock and Swing
allow the swing to be operated. lock ON OFF ON OFF
switch
fl Even when the swing lock prolix switch is
turned ON, the swing lock switch stays ON Swing hold-
Swing Swing lock Swing lock Swing lock
ing brake
and the swing brake is not canceled. brake applied canceled applied
applied
fl 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, 800-6 10-139


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

6. Engine automatic warming-up device, overheat prevention function, turbo protect


function, split injection function

Function
• If the water temperature is low, this auto-
matically raises the engine speed to warm
up the engine after it is started. In addition,
if the water temperature rises too high dur-
ing operations, it reduces the load of the
pump to prevent overheating.
• To protect the turbocharger bearing during
cold weather, the engine speed is kept be-
low 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 injec-
tion.

10-140 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

1) Engine automatic warming-up function


• After the engine is started, if the engine cool-
ant temperature is low, the engine speed is
automatically raised to warm up the engine.

Conditions for actuation (both are necessary) Actuation

Coolant temperature: Less than 30°C Engine speed: 1200 rpm


Engine speed: Less than 1200 rpm

Conditions for cancellation (any one) Cancellation


Coolant temperature: 30°C or above
Auto-
matic Automatic warming-up time: 10 minutes or more Engine speed: As desired
Fuel control dial: Held at more than 70% of
Manual full throttle for more than 3 seconds

2) Engine overheat prevention function


• This function protects the engine by lower-
ing the pump load and engine speed to pre-
vent overheating when the engine coolant
temperature has risen too high.
• This system is actuated at 105°C and above.

Actuation condition Actuation, remedy

Water temperature: Working mode : In any mode


105°C and above Engine speed : Low idling
(Water temperature gauge: Monitor warning lamp : Lights up
Red range) Alarm buzzer : Sounds

Cancel condition

Water temperature: Below 105°C


Fuel control dial : Return temporarily
to low idling position

• When the above conditions are met, the


system returns to the condition before
the overheat prevention function was
actuated (manual reset).

PC750, 800-6 10-141


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 Turbo protect time
temperature (sec)
More than +10°C 0
Gradually changes
+10°C to –10°C between 0 and 5
Less than –10°C 5

Engine speed: 1000 rpm

Even if the fuel control dial is operated dur-


ing 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 start-
ing the main injection.
As a result, the lower idling speed during
this time becomes slightly higher.

Actuation condition
Water Split injection time
temperature (sec)
More than 20°C 0
20°C to –30°C 0 – 15
Less than –30°C 15

10-142 PC750, 800-6


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 Travel speed Travel motor


Travel speed Remarks
switch solenoid valve swash plate angle

Low speed Suitable for traveling down-


Lo De-energized Max.
(max 2.7 km/h) hill or on rough ground

Max. Low speed (2.7 km/h) Suitable for use when


Hi Excited ↕ ↔ High speed (4.2 km/h) moving long distances
Min

PC750, 800-6 10-143


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 Cancel solenoid Boom shockless
Remarks
switch valve control

ON
De-energized ON Suitable for normal operations
(Contacts open)

OFF Suitable for compacting or


Excited Canceled
(Contacts closed) 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.

10-144 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

9. Straight-travel function

Outline
• When the travel is operated at the same time • To prevent this, the straight-travel valve is
as the boom, arm, or bucket, the pressure switched to interconnect the left and right
oil flowing to the left and right travel circuits travel circuits. This ensures that the amount
is divided and sent to the boom, arm, or of oil supplied to the left and right travel
bucket circuit. motors is equal, so the left and right travel
If the oil in one travel circuit is divided off, motors both rotate at the same speed, and
the amount of oil supplied to the travel mo- this prevents any travel deviation.
tor 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 ma-
chine to deviate.

PC750, 800-6 10-145


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

Operation
Work equipment
Left and right Straight-travel Straight-travel
control lever, Remarks
travel levers solenoid valve valve
swing lever

Left and right travel motor


Neutral De-energize Not actuated
circuits independent
Operation
Left and right travel motor
Operated Excited Actuated
circuits assist

10-146 PC750, 800-6


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 match-
ing of the boom RAISE and swing. This di-
vides the flow to provide a swing speed
which matches the swing angle, thereby en-
abling the operator to carry out compound
operations easily.

Loading a dump truck on the same ground


Swing prioritymode OFF:
{ Swinging by 90 degrees and loading a dump truck

Swing priority mode ON:


{ Swinging by 180 degrees and loading a dump truck
Loading a dump truck from a bench

PC750, 800-6 10-147


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.
Swing priority
Solenoid
selector valve
Swing priority
OFF
mode OFF ON
(de-energized)
(standard)
Swing priority
ON
mode ON OFF
(excited)
(swing priority)

10-148 PC750, 800-6


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 approxi-
mately 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.

PC750, 800-6 10-149


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

12. Components of system


1) Engine speed sensor

1. Wire Function
2. Magnet • The engine speed sensor is installed to the
3. Terminal ring gear portion of the engine flywheel. It
4. Housing counts electrically the number of gear teeth
5. Connector 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 operat-
ing condition of each actuator
is detected from the PPC pres-
sure, and this is sent to the
engine controller and pump
controller.

10-150 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

3) TVC prolix resistor

1 2

SBP00370

1. Resistor
2. Connector

Specification Function
Resistance: 20 Ω • 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


fl See ENGINE CONTROL.

5) Monitor panel
fl See MACHINE MONITOR SYSTEM.

6) TVC valve
fl See HYDRAULIC PUMP.

PC750, 800-6 10-151


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

7) Pump controller

10-152 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

Input and output signals


CN1 CN3 CN4
Pin Name of signal Input/ Pin Name of signal Input/ Pin Name of signal Input/
No. output No. output No. output
1 Step light relay Output 1 NC 1 NC Input
2 Straight travel solenoid Output 2 Fuel level sensor Input 2 NC Input
3 Swing brake solenoid Output 3 NC 3 RS232C TXD Output
4 Auto decel signal output Output 4 NC 4 RS232C RXD Input
5 Swing priority changeover solenoid Output 5 NC Input,
5 NC
6 GND 6 NC output

7 Power supply (+24 V) 7 NC Input,


6 NC
output
8 CO cancel solenoid Output 8 Start switch (Acc) Input
7 NC Input
9 Travel hi/lo change solenoid Output 9 NC
8 Flash write switch Input
10 2-stage relief solenoid Output 10 Left travel pressure switch Input
9 NC
11 Flash light relay Output 11 Hydraulic oil temp. Input
10 RS232C GND
12 GND 12 Charging level Input
Input,
13 Power supply (+24 V) 13 NC 11 NC
output
CN2 14 NC Input,
12 NC
Pin Input/ 15 NC output
Name of signal
No. output 16 GND CN7
1 Power supply (+24 V) 17 NC Pin Name of signal Input/
2 NC 18 Start switch (C) Input No. output
3 NC 19 (Auto grease-up) Input 1 Engine speed
4 NC 20 NC 2 Engine speed Input
5 NC 21 NC 3 GND
6 Power supply relay for step light Output 22 Boom raise switch Input 4 GND
7 NC 23 Arm curl switch Input 5 Swing switch Input
8 TVC solenoid (+) Output Input, 6 Input
24 Network (+)
9 NC output 7 Step light switch Input
10 NC 25 Machine select 1 Input 8 Coolant level Input
11 GND 26 Machine select 3 Input 9 Hydraulic oil level Input
12 Power supply (+24 V) 27 Machine select 5 Input 10 GND (PLUS)
13 NC 28 Swing prolix switch Input 11 Bucket curl switch Input
14 NC 29 (Over load sensor) Input 12 Bucket dump switch Input
15 NC 30 Boom lower switch Input 13 Travel switch Input
16 NC 31 Arm dump switch Input 14 Service switch Input
17 NC Input, 15 Horn switch Input
32 Network (+)
output 16 Engine oil level Input
18 TVC solenoid (–) Output
33 Machine select 2 Input 17 Air cleaner Input
19 NC
34 Machine select 4 Input
20 NC
35 Kerosene mode select Input
21 GND
36 Swing lock switch Input

PC750, 800-6 10-153


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

MONITOR SYSTEM

Function
• The monitor system uses the sensors in- • The monitor panel also has various built-in
stalled to all parts of the machine to observe mode selector switches, and functions as the
the condition of the machine. It processes control panel for the machine control sys-
this information swiftly, and displays it on a tem.
panel to inform the operator of the condi-
tion of the machine.
• The content of the information displayed on
the machine can broadly be divided as fol-
lows.
1. Monitor portion
This gives an alarm if any abnormality oc-
curs in the machine.
2. Gauge portion
This always displays the condition of the
machine (coolant temperature, fuel level).

10-154 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

MONITOR PANEL

Outline
• The monitor panel consists of the switches Input and output signals
for the monitor display functions, mode se- CN-P01 CN-P02
lector, and electrical components. Pin No. Name of signal Pin No. Name of signal
• It has a built-in CPU (Central Processing Unit), 1 NC 1 GND
2 NC 2 Washer output
and processes, displays, and outputs the in- 3 NC 3 Wiper signal
formation. 4 N/W signal 4 Wiper SW (ON)
• The monitor display panel uses a liquid crys- 5 Swing lock 5 Wiper SW (WASHER)
6 Buzzer stop 6 Wiper limit SW
tal display (LCD) and LED lamp. The mode 7 Buzzer output 7 NC
switches are flat sheet switches. 8 Lamp 8 +VB
9 Key ON signal 9 GND
10 Acc signal 10 Washer output
11 N/W signal 11 Motor forward revolution
12 NC 12 Wiper SW (INT)
13 NC 13 Window limit SW
14 N/W GND 14 +VB
15 NC 15 Wiper limit SW
16 NC 16 NC
17 NC
18 Preheating
19 Start signal
20 NC

PC750, 800-6 10-155


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

MONITOR DISPLAY

1. Clock
2. Service meter
3. Fuel level gauge
4. Fuel level caution lamp
5. Engine oil level caution lamp
6. Hydraulic oil level caution lamp
7. Preheating pilot lamp
8. Swing holding brake pilot lamp
9. Oil maintenance pilot lamp
10. Battery charge caution lamp
11. Air cleaner clogging caution lamp
12. Hydraulic oil temperature caution lamp
13. Engine oil pressure caution lamp
14. Coolant level caution lamp
15. Coolant temperature caution lamp
16. Coolant temperature gauge

10-156 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

Content of display

Symbol Display item Display range When engine is stopped When engine is running

Flashes and buzzer


Coolant level Below low level Flashes when abnormal
sounds when abnormal
SAP00519

Below 600 rpm:


above 0.05 MPa
Lights up when normal
Engine oil {0.5 kg/cm2} Flashes and buzzer sounds
(goes out when engine
pressure Above 1300 rpm: starts) when abnormal
SAP00520
above 0.15 MPa
{1.5 kg/cm2}

Air cleaner
When clogged OFF Flashes when abnormal
clogging
SAP00521

Lights up when normal


When charging is
Charge level (goes out when engine Flashes when abnormal
defective
SAP00522 starts)

Engine oil level Below low level Flashes when abnormal OFF
SAP00523

Hydraulic oil level Below low level Flashes when abnormal OFF
SAP00524

Parking When swing is Lights up when swing lock switch is ON, flashes
(Swing lock) locked when swing lock prolix switch is ON
SAT00098

Oil maintenance See next page. OIL MAINTENANCE FUNCTION


SAP02732

When glow plug is preheating: ON; when glow plug


When APS is has completed preheating: OFF; when engine coolant
Preheating temperature is above set temperature: Flashes (2 times/
actuated
SAP00526 3 seconds), then goes OFF

Coolant Flashes when above 102°C, flashes and


temperature buzzer sounds when above 105°C
SAP00527

Fuel level Flashes when below low level


SAP00528

Hydraulic oil Above specified Flashes and buzzer sounds


OFF
temperature level when abnormal
SAD01484

PC750, 800-6 10-157


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

OIL MAINTENANCE FUNCTION

1. Function, operation
The oil maintenance function uses LED lamps
on the monitor panel to inform the operator
at a fixed interval after the engine oil is
changed that the oil change interval has been
reached.
At the same time, it also functions to display
the service contact telephone number on the
liquid crystal display.
1) Confirmation of elapsed time
Normally, no display is given until the
elapsed time reaches the point B on the
right diagram after reset. However, if
the buzzer cancel switch is pressed and
the key is turned to the ON position (with
the buzzer cancel switch hold for 2.5 sec-
onds), the elapsed time is displayed on
the service meter display.
2) Oil change display
When the elapsed time has reached or
passed the point B on the right diagram,
the service meter display gives the
elapsed time and the LED flashes when
the key is turned ON.

2. Setting change interval


1) The change interval can be set by using
the interval setting mode. The time that
can be set are [125 h], [250 h], [500 h],
[no setting], and [demo mode]. The de-
fault setting is [no setting].
2) To enter the change interval setting
mode, keep the time switch and active
mode switch (swing priority switch)
pressed simultaneously for 2.5 seconds.
3) If the buzzer cancel switch is pressed in
the change interval setting mode, the
time display will change from […] →
[125] → [250] → [500] → [ d] ([…] indi-
cates [no setting] and [ d] indicates
[demo mode]).
4) To save the change interval time, set the
monitor panel display to the desired time
(mode), then keep the time switch and
active mode switch (swing priority
switch) pressed simultaneously for 2.5
seconds.

10-158 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

3. Display timing, content


1) Oil change display
After all the lamps light up, the elapsed
time is displayed for 10 seconds. For the
next 10 seconds, the telephone number
is displayed.
However, if no telephone number has
been input, the elapsed time is displayed
for 20 seconds after all the lamps light
up.
2) Elapsed time confirmation
After all the lamps light up, the elapsed
time is displayed for 10 seconds.

4. Elapsed time reset


1) During the oil change interval display and
the elapsed time display, for 10 seconds
after all lamps light up (during the
elapsed time display), if the buzzer can-
cel switch is pressed and held for 3 sec-
onds, the elapsed time is reset. When
the elapsed time is reset, the elapsed
time shows [0h] for 1 second.
2) When the set time is changed, the
elapsed time is reset to 0h.

5. Demo mode
1) The set time in the demo mode is 250h
and the elapsed time is set to 240h. When
the key is turned ON, the oil change dis-
play is given. However, the elapsed time
does not increase.
It is also possible to carry out the reset
operation during this display.
In the demo mode, after the key is turned
ON three times, the interval setting is
automatically set to [no setting] from the
4th time. In addition, the elapsed time is
reset to 0h and the elapsed time count
starts.

PC750, 800-6 10-159


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

SWITCHES

1. Working mode switch


2. Auto deceleration switch
3. Swing priority mode switch
4. Travel speed switch
5. Knob button switch (Heavy lift)

• There are five mode selector switches on Switch actuation table


the switch panel. Each time any of these
Item Actuation
switches is pressed, the condition of the
machine will change. The LEDs on the switch Working mode DH ↔ H ↔ G
panel light up to indicate the condition of
Heavy lift button OFF ↔ ON
the machine.
Auto decel ON ↔ OFF
Travel speed Hi ↔ Lo
Swing priority OFF ↔ ON

fl The bold letters indicate the default position


of the switch when the starting switch is
turned ON.

10-160 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS

SENSORS
• The signals from the sensors are input di-
rectly to the engine controller and the pump
controller.
The contact type sensors are always con-
nected at one end to the chassis GND.

Name of sensor Type of sensor When normal When abnormal Input controller

Coolant level Contact type ON (closed) OFF (open) Pump controller

Engine oil level Contact type ON (closed) OFF (open) Pump controller

Hydraulic oil level Contact type ON (closed) OFF (open) Pump controller

Engine oil pressure Contact type OFF (open) ON (closed) Engine controller

Coolant temperature Resistance type — — Engine controller

Fuel level Resistance type — — Pump controller

Air cleaner clogging Contact type OFF (closed) ON (open) Pump controller
Hydraulic oil temperature Contact type ON (closed) OFF (open) Pump controller

Coolant level sensor

1. Sub-tank
2. Float
3. Sensor
4. Connector

PC750, 800-6 10-161


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS

Engine oil level sensor


Hydraulic oil level sensor

1. Connector
2. Bracket
3. Float
4. Switch

Engine oil pressure sensor

1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal

Air cleaner clogging sensor

10-162 PC750, 800-6


STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS

Fuel level sensor

1. Float
2. Connector
3. Cover
4. Variable resistor

Coolant temperature sensor


Hydraulic oil temperature sensor

1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector

PC750, 800-6 10-163


20 TESTING AND ADJUSTING

Standard value table for engine ......................... 20- 2 Adjusting engine speed sensor ......................... 20- 45
Standard value table for chassis ......................... 20- 3 Testing and adjusting hydraulic pressure
Standard value table for electrical parts ............ 20-12 in work equipment, swing, travel circuit .. 20- 46
Tools for testing, adjusting, Testing and adjusting control pump
and troubleshooting ...................................... 20-25 circuit oil pressure ....................................... 20- 49
Measuring air supply pressure Testing and adjusting
(boost pressure) ............................................. 20-28 piston pump control pressure .................... 20- 51
Measuring exhaust temperature ......................... 20-29 Measuring servo piston stroke .......................... 20- 57
Measuring exhaust color ..................................... 20-30 Measuring PPC valve output pressure ............. 20- 58
Adjusting valve clearance .................................... 20-31 Testing solenoid valve output pressure ........... 20- 59
Measuring blow-by pressure ............................... 20-32 Adjusting work equipment
Measuring compression pressure ....................... 20-32 swing PPC valve .......................................... 20- 60
Measuring engine oil pressure ........................... 20-33 Testing travel deviation ...................................... 20- 61
Handling equipment in fuel circuit ..................... 20-34 Testing locations causing hydraulic
Releasing remaining pressure in fuel system ... 20-34 drift of work equipment .............................. 20- 64
Measuring fuel pressure ...................................... 20-35 Measuring oil leakage ........................................ 20- 65
Reduced cylinder mode operation for engine ... 20-36 Testing clearance of swing circle bearing ....... 20- 70
Bleeding air from fuel circuit............................... 20-38 Testing and adjusting track shoe tension ........ 20- 71
Checking for leakage in fuel circuit .................... 20-40 Bleeding air ......................................................... 20- 72
Testing and adjusting alternator belt tension ... 20-41 Releasing remaining pressure
Testing and adjusting fan belt tension .............. 20-42 in hydraulic circuit ....................................... 20- 74
Testing and adjusting air conditioner Procedure for checking diode ........................... 20- 75
compressor drive belt tension ..................... 20-43
Handling engine controller TROUBLESHOOTING .......................................... 20-101
high voltage circuit ........................................ 20-44

PC750, 800-6 20-1


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE


PC750-6
Machine model PC800-6

Engine SAA6D140E-3

Item Measurement condition Unit Standard value Permissible value

High idling (DH mode) 1,980 ± 50 1,980 ± 50

Engine speed Low idling rpm 825 ± 25 825 ± 25

Rated speed (DH mode) 1,800 —

Intake air pressure At rated output kPa Min 147 {Min. 1,100} 117 {880}
{mmHg}

Exhaust gas pressure All speed range °C Max. 700 Max. 750
(intake air temp: 20°C)

At sudden acceleration Max. 4.0 7.0


Exhaust gas color Bosch
At high idling index Max. 1.0 2.0

(normal temperature)
Valve clearance Intake valve mm 0.35 —

Exhaust valve 0.57 —

Oil temperature:
40 – 60°C
Compression pressure (Engine speed: MPa Min. 4.1 {Min. 42} 2.8 {29}
160 – 200 rpm) {kg/cm2}
(SAE30 oil)

(Coolant temperature:
Blow-by pressure within operating range) kPa
(SAE30 oil) {mmH2O} Max. 1.96 {Max. 200} 3.9 {400}

At rated output

(Coolant temperature:
within operating range)
At high idling MPa 0.34 – 0.54 {3.5 – 5.5} 0.21 {2.1}
Oil pressure {kg/cm2}
At low idling Min. 0.12 {Min. 1.2} 0.08 {0.8}
(SAE30)
At low idling Min. 0.1 {Min. 1.0} 0.07 {0.7}
(SAE10W)

All speed range


Oil temperature (inside oil pan) °C 90 – 110 120

deg.
Fuel injection timing B. T. D. C. (°) Electric control —

Deflection when pressed


Alternator belt tension with finger force of mm 10 – 15 10 – 15
approx. 58.8 N {6 kg}

Deflection when pressed


Air compressor with finger force of mm 10 – 15 10 – 15
belt tension approx. 58.8 N {6 kg}

20-2 PC750, 800-6


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS


fl The Standard value for new machine and Service limit value in the table below are all values when
measured in the D.H mode.

Applicable model PC750-6


PC800-6
Cate- Standard value Service limit
gory Item Measurement conditions Unit for new machine value
· Engine water temperature:
Within operating range
· Hydraulic oil temperature:
All pumps at relief 45 – 55°C 1,770 ± 100 1,770 ± 100
· Engine at full throttle
· In D.H mode
Engine speed

· Boom up relief

· Engine at full throttle rpm


All pumps at relief · In D.H mode
+ · Boom up relief 1,770 ± 100 1,770 ± 100
heavy lift +
heavy lift ON

Engine speed when · Auto-deceleration switch ON


auto-deceleration is · Fuel control dial at MAX. 1,400 ± 100 1,400 ± 100
actuated · Control levers at neutral.

Boom Lo control valve ¬ a b ¬ a b

¬
Boom Hi control valve
a b
Arm Lo control valve
Spool stroke

Arm Hi control valve

Bucket Lo control valve 111.5 16±0.5 16±0.5 111.5 16±0.5 16±0.5

Bucket Hi control valve

Travel control valve BLP00101 mm

Swing control valve

Boom control lever · Center of lever knob 85 ± 10 85 ± 10


Travel of control levers

· Read max. value to end of


Arm control lever travel 85 ± 10 85 ± 10
· Engine stopped
Bucket control lever · Exclude play at neutral. 85 ± 10 85 ± 10

Travel control lever 115 ± 15 115 ± 15

Swing control lever 85 ± 10 85 ± 10

PC750, 800-6 20-3


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC750-6


PC800-6
Cate- Item Measurement conditions Standard value
Unit for Service limit
gory new machine value
Operating effort of control levers

Boom control lever · Engine at full throttle 15.7 ± 4.9 {1.6 ± 0.5} 15.7 ± 4.9 {1.6 ± 0.5}
· Oil temperature: 45 – 55°C
Arm control lever · Fit push-pull scale to center 15.7 ± 4.9 {1.6 ± 0.5} 15.7 ± 4.9 {1.6 ± 0.5}
of control lever knob or tip
Bucket control lever of pedal to measure N {kg} 12.7 ± 3.9 {1.3 ± 0.4} 12.7 ± 3.9 {1.3 ± 0.4}
· Measure max. value to end
Swing control lever of travel 12.7 ± 3.9 {1.3 ± 0.4} 12.7 ± 3.9 {1.3 ± 0.4}

Travel control lever Lever 24.5 ± 5.9 {2.5 ± 0.6} 24.5 ± 5.9 {2.5 ± 0.6}

Normal 31.4 ± 1.0 {320 ± 10} 31.4 +1.0 +10


–2.0 {320 –20 }
RAISE
At heavy lift 33.8 ± 1.0 {345 ± 10} 33.8 +1.0 +10
–2.0 {345 –20 }
Boom
Normal 18.6 ± 1.9 {190 ± 20} 18.6 ± 1.9 {190 ± 20}
LOWER
At machine
push-up 31.4 ± 1.0 {320 ± 10} 31.4 +1.0 +10
–2.0 {320 –20 }

Arm · Engine at full 31.4 ± 1.0 {320 ± 10} 31.4 +1.0 +10
–2.0 {320 –20 }

throttle
· Oil tempera- Curl 31.4 ± 1.0 {320 ± 10} 31.4 +1.0 +10
–2.0 {320 –20 }
Bucket ture: 45 – 55°C
Hydraulic pressure

Dump 32.4 ± 1.0 {330 ± 10} 32.4 ± 1.0 {330 ± 10}


· Relieve only
circuit being At each side MPa
Travel relief {kg/ 32.4 ± 1.0 {330 ± 10} 32.4 +1.0 +10
–2.0 {330 –20 }
measured
· In D.H mode cm2} +2.5
Swing 28.4 –0.5 {290+25
–5 } 28.4 +2.5 +25
–0.5 {290 –5 }

Control pump 3.33 +0.49


+0 {34 +5
+0 } 3.33 +0.49
+0 {34 +5
+0 }

· Engine at full Levers at


neutral 2.21 ± 0.2 {22.5 ± 2} Min. 1.76 {Min. 18}
throttle
TVC valve output · Oil tempera- Boom RAISE
pressure relief (standard) 1.23 ± 0.2 {12.5 ± 2} 1.18 ± 0.2 {12 ± 2}
ture: 45 – 55°C
· In D.H mode Heavy lift ON,
boom RAISE relief 1.19 ± 0.2 {12.1 ± 2} 1.14 ± 0.2 {11.6 ± 2}

· Engine at full Levers at


neutral Max. 0.4 {Max. 4} Max. 0.55 {Max.5.5}
NC valve output throttle
pressure · Oil tempera- Travel lever at full,
ture: 45 – 55°C tracks rotating Min. 1.67 {Min. 17} Min. 1.67 {Min. 17}
· In D.H mode under no load
(note)

20-4 PC750, 800-6


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC750-6


PC800-6
Cate- Item Measurement conditions Standard value
Unit for Service limit
gory new machine value
Control · Engine at full
levers at throttle Min. 1.14 {Min. 11.6} Min. 1.14 {Min. 11.6}
Jet sensor neutral · Hydraulic oil
temperature:
Hydraulic pressure

differential
pressure Control 45 – 55°C
levers at Max. 0.15 {Max. 1.5} Max. 0.15 {Max. 1.5}
end of (Pump discharge pressure MPa
travel at any value) {kg/
· Hydraulic oil temperature: cm2}
45 – 55°C
· Difference between relief
Drop in hydraulic pressure with engine at full Max. 2.0 {Max. 20} Max. 2.9 {Max. 30}
pressure throttle and relief pressure
with engine at low idling
(relief pressure: 2-pump relief)

Overrun when · Engine at full throttle deg. Max. 60 Max. 80


stopping swing · Hydraulic oil temperature: <mm> <Max. 1,035> <Max.1,380>
45 – 55°C
· Stop after swinging one turn and
measure distance that swing circle
moves
Value in < > shows distance at
outside circumference of swing circle

90° 4.4 ± 0.5 Max. 5.3


Swing

Time taken to
start swing · Engine at full throttle
· Hydraulic oil temperature:
45 – 55°C
· In D.H mode 180° 6.8 ± 0.7 Max. 8.2
· Time taken to swing 90°
and 180° from starting
position sec

Time taken to swing 41.0 – 47.0 Max. 50


· Engine at full throttle
· Hydraulic oil temperature:
45 – 55°C
· In D.H mode
· Swing one turn, then measure
time taken to swing next 5 turns

PC750, 800-6 20-5


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC750-6


PC800-6
Cate- Item Measurement conditions Standard value
Unit for Service limit
gory new machine value

15°

BKP00103

· Engine stopped
Hydraulic drift of swing · Hydraulic oil temperature: mm 0 0
Swing

45 – 55°C
· Set machine on 15° slope, and
set upper structure at 90° to
the side.
· Make match marks on swing
circle outer race and track
frame.
· Measure distance that match
marks move apart after 5
minutes.
· Engine at full throttle
Leakage from swing · Hydraulic oil temperature: ¬ /min Max. 5 Max. 10
motor 45 – 55°C
· Relieve swing circuit.
Low speed

76.5 – 93.5 76.5 – 93.5

BKP00104

Travel speed (1)


· Engine at full throttle
· Hydraulic oil temperature:
High speed

45 – 55°C
· In D.H mode
· Raise track on one side at 48 – 59 48 – 59
a time, rotate one turn,
then measure time taken
for next 5 turns with no
Travel

load. sec

45˚
Low speed

23 – 31 23 – 31

BKP00105

Travel speed (2)


· Engine at full throttle
· Hydraulic oil temperature:
High speed

45 – 55°C
· In D.H mode
15 – 19 15 – 19
· Run up for at least 10 m,
and measure time taken
to travel next 20 m on flat
ground.

20-6 PC750, 800-6


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC750-6


PC800-6
Cate- Item Measurement conditions Standard value
Unit for Service limit
gory new machine value
Work equipment posture

45°

BKP00106

· Engine at full throttle


· Hydraulic oil temperature:
45 – 55°C
· In D.H mode
· Travel speed : Hi
Travel deviation · Run up for at least 10 m, and
measure deviation when Max. 200 Max. 200
traveling next 20 m on flat
ground.
fl Use a hard horizontal surface.
mm
20m

10m BKP00107

fl Measure dimension χ.
Travel

12˚

BKP00108

Hydraulic drift of travel 0 0


· Engine stopped
· Hydraulic oil temperature:
45 – 55°C
· Stop machine on 12° slope
with sprocket at uphill end of
machine.
· Measure the distance the
machine moves in 5 minutes.

Leakage of travel motor ¬ /min Max. 20 Max. 40


· Engine at full throttle
· Hydraulic oil temperature:
45 – 55°C
· Lock shoes and relieve travel
circuit.
· At each side

PC750, 800-6 20-7


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC750-6


PC800-6
Cate- Item Measurement conditions Standard value
Unit for Service limit
gory new machine value
Work equipment posture PC750-6 PC750-6
Back hoe Backhoe Loading Backhoe Loading
Total work equip- shovel shovel
ment
(hydraulic drift at
tip of bucket teeth) Max. 1,400 Max. 1,500 Max. 1,800 Max. 1,800
(Max. 900) (Max. 1000)
BKP00110
Loading shovel
Hydraulic drift of work equipment

Boom cylinder
(amount of retrac- Max. 60 Max. 90
Max. 150 Max. 230
tion of cylinder) (Max. 35) (Max. 50)

· Place in above posture and


measure extension or retraction
of each cylinder and downward mm
movement at tip of bucket teeth.
Rated load of work equipment
Backhoe specification:
Arm cylinder 49 kN {5000 kg}
(amount of exten- SE specification: 64 kN {6500 kg} Max. 165 Max. 250
Max. 30 Max. 45
sion of cylinder) Loading shovel specification: (Max. 70) (Max. 105)
with bucket link: 67 kN {6800 kg}
without bucket link: 79 kN {8100 kg}
· Horizontal, flat ground
· Levers at neutral
· Engine stopped
· Hydraulic oil temperature:
Work equipment

45 – 55°C
· Start measuring immediately
Bucket cylinder after setting. Max. 50 Max. 75
(amount of retrac- · Measure hydraulic drift every 5 Max. 8 Max. 12
tion of cylinder) minutes, and judge from results (Max. 15) (Max. 25)
for 15 minutes.
· Figures in ( ) are value when
bucket is not loaded.
PC750: PC750:
RAISE (note)

4.9 ± 0.5 Max. 6.3


PC800: PC800:
Boom 4.9 ± 0.5 Max. 6.3
Bucket teeth in PC750·800SE: PC750·800SE:
contact with ground 5.2 ± 0.5 Max. 6.8

PC750: PC750:
4.3 ± 0.4 Max. 5.1
Work equipment speed

Cylinder fully
LOWER

extended · Engine at full throttle PC800: PC800:


· Hydraulic oil temperature: 4.2 ± 0.4 Max. 5.0
45 – 55°C PC750·800SE: PC750·800SE:
· In D.H mode 4.4 ± 0.4 Max. 5.2
sec
PC750: PC750:
4.5 ± 0.5 Max. 5.7
IN (note)

PC800: PC800:
Arm
5.2 ± 0.5 Max. 6.4
Cylinder fully
retracted PC750·800SE: PC750·800SE:
5.2 ± 0.5 Max. 6.4

PC750: PC750:
Fully extended 3.4 ± 0.3 Max. 4.4
· Engine at full throttle
OUT

PC800: PC800:
· Hydraulic oil temperature: 3.9 ± 0.4 Max. 4.9
45 – 55°C
PC750·800SE: PC750·800SE:
· In D.H mode
3.9 ± 0.4 Max. 4.9
Note: Include cylinder cushion operating time.
20-8 PC750, 800-6
(3)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC750-6


PC800-6
Cate- Item Measurement conditions Standard value
Unit for Service limit
gory new machine value
PC750: PC750:

CURL (note)
3.3 ± 0.3 Max. 3.9
PC800: PC800:
3.6 ± 0.4 Max. 4.4
Bucket PC750·800SE: PC750·800SE:
Cylinder fully
4.6 ± 0.5 Max. 5.6
retracted
PC750: PC750:

3.5 ± 0.3 Max. 4.1

DUMP
Fully extended · Engine at full throttle PC800: PC800:
· Hydraulic oil temperature: 3.7 ± 0.3 Max. 4.3
45 – 55°C PC750·800SE: PC750·800SE:
· In D.H mode 4.2 ± 0.4 Max. 5.0
PC750 Loading shovel PC750 Loading shovel
Work equipment posture
CURL (note)
Work equipment speed

With Without With Without


bucket link bucket link bucket link bucket link

Bucket 4.3 ± 0.4 4.4 ± 0.4 — —


Cylinder fully
retracted

DUMP

Fully extended · Engine at full throttle


Work equipment

· Hydraulic oil temperature: 4.0 ± 0.4 4.1 ± 0.1 — —


45 – 55°C
· In D.H mode sec
(PC750 Loading shovel)
OPEN

Bottom dump — —
Cylinder fully
retracted

CLOSE

Fully extended
· Engine at full throttle — —
· Hydraulic oil temperature:
(PC750 Loading shovel) 45 – 55°C
Time lag

BKP00114
Boom Max. 6 Max. 6
· Lower boom and measure time
taken from point where bucket
contacts ground to point where
chassis rises from ground
· Engine at low idling
· Hydraulic oil temperature:
45 – 55°C

Note: Include cylinder cushion operating time.

PC750, 800-6 20-9


(3)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC750-6


PC800-6
Cate- Item Measurement conditions Standard value
Unit for Service limit
gory new machine value

BKP00115
Arm Max. 5 Max. 5
· Stop arm suddenly and
measure time taken for arm to
stop
· Engine at low idling
· Hydraulic oil temperature:
45 – 55°C
Time lag

BKP00116
Bucket sec Max. 4 Max. 4
Work equipment

· Stop bucket suddenly and


measure time taken for bucket
to stop
· Engine at low idling
· Hydraulic oil temperature:
45 – 55°C

Bottom dump · Time taken for bottom dump — —


to move again when opereted
from max. bottom open
position to close position and
stopped temporarily.
· Engine at low idling
(PC750 Loading shovel)
· Hydraulic oil temperature:
45 – 55°C
Internal oil leakage

· Hydraulic oil temperature:


Cylinders Max. 5 Max. 20
45 – 55°C
· Hydraulic oil pressure:
cc/min
31.4 ± 1.0 MPa {320 ± 10 kg/cm2}
Center swivel joint Max. 10 Max. 100

20-10 PC750, 800-6


(3)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

HPV95 + 95 (No.1 pump)


Cate-
gory PC750, 800-6: Discharge amount of one main piston pump (in H mode)
Performance of hydraulic pump

• TVC current : 0.4A


• Pump speed: At 2,400 rpm (Engine rated speed at 1,800 rpm)
Test pump Discharge Average Standard value Judgement
discharge pressure of pressure for discharge standard lower
Check point pressure other pump amount limit
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2}) Q (¬/min) Q (¬/min)
P1 + P2
As desired P1 P2 See graph See graph
2

fl 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.
fl 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, 800-6 20-11


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

STANDARD VALUE TABLE FOR ELECTRICAL PARTS


Sys- Name of Connector Inspection Measurement
Judgment table
tem component No. method conditions
If the condition is as shown in the table 1) Turn starting

resistance
below, it is normal switch OFF.

Measure
2) Disconnect
Ne rotation sensor NE (male) Between (1) and (2) 85 – 210 Ω connector NE.
Between (1)(2) and chassis Min. 1 MΩ

If the condition is as shown in the table 1) Turn starting


switch OFF.
resistance
below, it is normal
Measure

2) Disconnect
G rotation sensor G (male) Between (1) and (2) 1.4 k – 3.5 kΩ connector G.
Between (1)(2) and chassis Min. 1 MΩ

If the condition is as shown in the table 1) Turn starting


below, it is normal switch OFF.
resistance
Measure

Engine water low 2) Disconnect


temperature sen- TWL Between (1) and (2) 9 k – 0.3 kΩ connector TWL.
sor (male) 3) Engine water
Between (1)(2) and chassis Min. 1 MΩ temp.:
10 – 100°C

If the condition is as shown in the table 1) Turn starting


resistance

below, it is normal switch OFF.


Measure
Engine controller system

Engine water high 2) Disconnect


temperature sen- TWH Between (1) and (2) 90 k – 3.5 kΩ connector TWH.
sor (male) 3) Engine water
Between (1)(2) and chassis Min. 1 MΩ temp. :
10 – 100°C

If the condition is as shown in the table 1) Turn starting


resistance

below, it is normal switch OFF.


Measure

2) Disconnect
Hydraulic oil low PSL Between Engine stopped Max.1 Ω connector PSL.
pressure switch (male) terminal and
sensor (chassis) At 600 rpm and up Min. 1 MΩ

If the condition is as shown in the table 1) Turn starting


below, it is normal switch OFF.
resistance
Measure

2) Disconnect
Hydraulic oil high PSH Between Engine stopped Max.1 Ω connector PSH.
pressure switch (male) terminal and
sensor (chassis) At 1,300 rpm and up Min. 1 MΩ

If the condition is as shown in the table 1) Insert T-


below, it is normal adapter into
Measure
voltage

Boost pressure E11 connectors


Between E12 (2) and (10) 4.6 – 5.4 V E11, E12.
sensor E12
2) Start engine.
Between E11(3) and CN2(10) 0.3 – 4.7 V

If the condition is as shown in the table 1) Turn starting


below, it is normal switch OFF.
resistance
Measure

2) Disconnect
Fuel temperature THL Between (1) and (2) 9 k – 0.3 kΩ connector THL.
sensor (male) 3) Fuel temp. :
Between (1)(2) and chassis Min. 1 MΩ 10 – 100°C

20-12 PC750, 800-6


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement


tem component No. method Judgment table conditions
If the condition is as shown in the table 1) Insert T-
below, it is normal adapter into

Measure
voltage
connectors
Common rail fuel E11 Between E12 (2) and (10) 4.6 – 5.4 V E11, E12.
pressure sensor E12 2) Start engine.
Between E11(1) and CN2(10) 0.3 – 4.7 V

If the condition is as shown in the table 1) Turn starting

resistance
below, it is normal switch OFF.
Measure 2) Disconnect
Fuel supply pump PCV1 Between (1) and (2) 2.3 – 5.3 Ω connector
PCV1 (male) PCV1.
Between (1)(2) and chassis Min. 1 MΩ

If the condition is as shown in the table 1) Turn starting


below, it is normal switch OFF.
resistance
Measure

2) Disconnect
Fuel supply pump PCV2 Between (1) and (2) 2.3 – 5.3 kΩ connector
PCV2 (male) PCV2.
Between (1)(2) and chassis Min. 1 MΩ

If the condition is as shown in the table 1) Turn starting


resistance

below, it is normal switch OFF.


Measure
Engine controller system

CN1 2) Disconnect
No. 1 fuel injector Between (1) and (2) 0.4 – 1.1 Ω connector CN1.
(male)
Between (1)(2) and chassis Min. 1 MΩ

If the condition is as shown in the table 1) Turn starting


resistance

below, it is normal switch OFF.


Measure

CN2 2) Disconnect
No. 2 fuel injector Between (1) and (2) 0.4 – 1.1 Ω connector CN2.
(male)
Between (1)(2) and chassis Min. 1 MΩ

If the condition is as shown in the table 1) Turn starting


below, it is normal switch OFF.
resistance
Measure

2) Disconnect
No. 3 fuel injector CN3 Between (1) and (2) 0.4 – 1.1 Ω connector CN3.
(male)
Between (1)(2) and chassis Min. 1 MΩ

If the condition is as shown in the table 1) Turn starting


resistance

below, it is normal switch OFF.


Measure

CN4 2) Disconnect
No. 4 fuel injector Between (1) and (2) 0.4 – 1.1 Ω connector CN4.
(male)
Between (1)(2) and chassis Min. 1 MΩ

If the condition is as shown in the table 1) Turn starting


below, it is normal
resistance

switch OFF.
Measure

CN5 2) Disconnect
No. 5 fuel injector Between (1) and (2) 0.4 – 1.1 Ω connector CN5.
(male)
Between (1)(2) and chassis Min. 1 MΩ

PC750, 800-6 20-13


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement


tem component No. method Judgment table conditions
If the condition is as shown in the table 1) Turn starting

resistance
Measure
below, it is normal switch OFF.
CN6 2) Disconnect
No. 6 fuel injector Between (1) and (2) 0.4 – 1.1 Ω connector CN6.
(male)
Between (1)(2) and chassis Min. 1 MΩ

If the condition is as shown in the table 1) Insert T-


Measure
below, it is normal adapter into
Fuel control dial E11 voltage Between E11 (4) and (11) 4.6 – 5.4 V connector E11.
2) Turn starting
Between E11 (6) and (11) 0.3 – 4.7 V switch ON.

If the condition is as shown in the table 1) Insert T-


Measure
voltage

below, it is normal adapter into


Main power
E14 Between (9)(20) and (8)(19) 20 – 30 V connector E14.
source 2) Turn starting
switch ON.

If the condition is as shown in the table 1) Insert T-


Measure

below, it is normal adapter into


voltage

connector E17.
Engine controller system

Power source E17 Between (6)(14) and (5)(13) 20 – 30 V


2) Turn starting
switch ON.

If the condition is as shown in the table 1) Insert T-


Measure

below, it is normal adapter into


voltage

Starting switch
ON (ACC) E14 Between (18) and (8)(19) 20 – 30 V connector E14.
signal 2) Turn starting
switch ON.
Engine controller

If the condition is as shown in the table 1) Insert T-


below, it is normal adapter into
Measure
voltage

Starting switch connector E14.


START (C) E14 Between (2) and (8)(19) 20 – 30 V 2) Turn starting
signal switch ON.

If the condition is as shown in the table 1) Insert T-


below, it is normal
Measure

adapter into
voltage

Auto-decelera- connector E14.


E14 Between Lever at neutral 18 – 30 V
tion signal 2) Turn starting
(11) and
Lever operated Max. 1 V switch ON.
(8)(19)

If the condition is as shown in the table 1) Insert T-


below, it is normal adapter into
Measure

connector E14.
voltage

Model Between (13) and (8)(19) Max. 1 V 2) Turn starting


selection E14 switch ON.
signal Between (14) and (8)(19) Max. 1 V

Between (15) and (8)(19) 20 – 30 V

20-14 PC750, 800-6


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement


Judgment table
tem component No. method conditions
If the condition is within the range shown 1) Turn starting

resistance
in the table below, it is normal. switch OFF.

Measure
ENE 2) Disconnect
Between (1) and (2) 500 – 1,000 Ω connector ENE.
(male)
Between (1)(2) and chassis Min. 1 MΩ

If the condition is within the range shown 1) Insert T-


in the table below, it is normal. adapter into
Measure
voltage
Engine speed connector ENE.
sensor ENE Between (1) and (2) 0.5 – 3.0 V 2) Start engine.
3) Measure at AC
range of tester.
Adjustment

1) Screw in rotation sensor until contacts


ring gear, then turn back 1 ± 1/6 turns.
— 2) If work normally when adjusted as above.

R.H. travel (forward) S01 If the condition is as shown in the table 1) Start engine
below, it is normal (or charge
Pump controller system

Boom RAISE S02 accumulator


Arm OUT S03 Between with engine
Lever at neutral Min. 1 MΩ stopped).
PPC pressure switch

(1)(male)
Measure resistance

Boom LOWER S04 and (2) 2) Disconnect


Arm IN S05 (male) Lever operated Max. 1 Ω connectors
S01 – S13.
Bucket CURL S06
Bucket DUMP S07
R.H. swing S08 Between (1)(male)(2)(male)
Min. 1 MΩ
and chassis
L.H. swing S10
R.H. travel (reverse) S11
L.H. travel (forward) S12
L.H. travel (reverse) S13

If the condition is as shown in the table 1) Turn starting


below, it is normal switch OFF.
2) Disconnect
continuity
Measure

When switch When switch connector X05.


Swing lock switch X05 is FREE is LOCK
(female)
Between (1) and (2) No continuity Continuity
Between (3) and (4) Continuity No continuity

If the condition is as shown in the table 1) Turn starting


below, it is normal switch OFF.
continuity

2) Disconnect
Measure

Swing holding When switch When switch harness.


SW01
brake release is OFF is ON
switch (switch)
Between (1) and (3) No continuity Continuity
Between (4) adn (6) No continuity Continuity

PC750, 800-6 20-15


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement


Judgment table
tem component No. method conditions
If the condition is as shown in the table 1) Turn starting
below, it is normal switch OFF.
When switch When switch 2) Disconnect
is OFF is ON connector C05.

Measure continuity
Between (3) and (1) Continuity No continuity
Between (3) and (5) No continuity Continuity
Emergency pump C05
drive switch (male) Between (4) and (2) Continuity No continuity
Between (4) and (9) No continuity Continuity
Between (8) and (6) Continuity No continuity
Between (8) and (10) No continuity Continuity
Between (7) and (9) Continuity No continuity

If the condition is within the range shown 1) Turn starting


resistance
Measure

in the table below, it is normal. switch OFF.


Emergency pump C06 2) Disconnect
drive resister (male) Between (1) and (2) 36 – 38 Ω connector C06.

If the condition is as shown in the table 1) Turn starting


below, it is normal switch OFF.
Measure resistance

Between Between Between Between 2) Disconnect


connector C09.
Pump controller system

(1) and (8) (2) and (8) (3) and (8) (4) and (8)
Model selection C09 No No No No
connector (female) Continuity Continuity Continuity Continuit
Between Between Between
(5) and (8) (6) and (8) (7) and (8)
No No Continuity
Continuity Continuity

If the condition is within the range shown 1) Turn starting


resistance
Measure

in the table below, it is normal. switch OFF.


C13 2) Disconnect
TVC solenoid Between (1) and (2) 10 – 22 Ω connector C13.
(male)
Between (1)(2) and chassis Min. 1 MΩ

If the condition is within the range shown 1) Turn starting


resistance
Measure

in the table below, it is normal. switch OFF.


2-stage relief V02 2) Disconnect
Between (1) and (2) 20 – 60 Ω connector V02.
solenoid (male)
Between (1)(2) and chassis Min. 1 MΩ

If the condition is within the range shown 1) Turn starting


resistance
Measure

Swing holding in the table below, it is normal. switch OFF.


V04 2) Disconnect
brake solenoid Between (1) and (2) 20 – 60 Ω
(male) connector V04.
valve
Between (2) and chassis Min. 1 MΩ

If the condition is within the range shown 1) Turn starting


resistance
Measure

in the table below, it is normal. switch OFF.


Travel speed V06 2) Disconnect
solenoid valve (male) Between (1) and (2) 20 – 60 Ω connector V06.
Between (2) and chassis Min. 1 MΩ

20-16 PC750, 800-6


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement


Judgment table
tem component No. method conditions
If the condition is within the range shown 1) Turn starting

resistance
in the table below, it is normal. switch OFF.

Measure
Straight-travel V03 2) Disconnect
Between (1) and (2) 20 – 60 Ω connector V03.
solenoid valve (male)
Between (2) and chassis Min. 1 MΩ

If the condition is within the range shown 1) Turn starting

resistance
in the table below, it is normal. switch OFF.
CO cancel V07 Measure 2) Disconnect
Between (1) and (2) 20 – 60 Ω connector V07.
solenoid valve (male)
Between (2) and chassis Min. 1 MΩ

If the condition is within the range shown 1) Turn starting


in the table below, it is normal. switch OFF.
resistance
Measure

Swing priority 2) Disconnect


selector solenoid V01 Between (1) and (2) 20 – 60 Ω connector V01.
valve (male)
Between (2) and chassis Min. 1 MΩ

If the condition is within the range shown 1) Turn step light


in the table below, it is normal.
Measure

switch ON.
voltage
Pump controller system

Step light M75 20 – 30 V 2) Turn step light


Between (1) and switch OFF.
revolving frame 0–3V

If the condition is within the range shown 1) Turn horn


in the table below, it is normal. switch ON.
Measure
voltage

20 – 30 V 2) Turn horn
Flash light M82 Between (1) and switch OFF.
revolving frame 0–3V

If the condition is within the range shown 1) Insert T-


in the table below, it is normal. adapter into
Measure
voltage

connector C01.
Main power Between (7)(13) and (6)(12) 20 – 30 V 2) Turn starting
C01
source switch ON.

If the condition is within the range shown 1) Insert T-


in the table below, it is normal.
Controller

adapter into
Measure
voltage

connector C02.
Solenoid Between (1)(12) and (11)(21) 20 – 30 V 2) Turn starting
C02
power source switch ON.

If the condition is within the range shown 1) Insert T-


in the table below, it is normal. adapter into
Measure
voltage

connectors
Swing lock C16 Between When swing lock switch C16, C17.
C17(16) FREE 20 – 30 V
switch C17 2) Turn starting
and When swing lock switch switch ON.
C16(3)(4) LOCK Max. 1 V

PC750, 800-6 20-17


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement


Judgment table
tem component No. method conditions
If the condition is within the range shown 1) Insert T-
in the table below, it is normal. adapter into

Measure
voltage
Engine speed connector C16.
C16 Between (2) and (1) 0.5 – 3.0 V 2) Turn starting
sensor
switch ON.
fl Measure at AC
range of tester.

Boom RAISE Between C17(2) and C16(3)(4) 1) Start engine.


2) Insert T-
Boom LOWER Between C17(10) and C16(3)(4) adapter.
Arm IN Between C17(3) and C16(3)(4)
Arm OUT Between C17(11) and C16(3)(4)
Bucket CURL Between C16(11) and C16(3)(4)
Measure

Bucket DUMP Between C16(12) and C16(3)(4)


voltage

C03
PPC pressure
C16 Swing Between C16(5) and C16(3)(4)
switch
C17 L.H. travel Between C03(10) and C16(3)(4)
R.H. travel Between C16(13) and C16(3)(4)

If the condition is within the range shown


Pump controller system

in the table below, it is normal.


Lever at neutral Lever operated
Controller

20 – 30 V Max. 1 V

If the condition is as shown in the table 1) Start engine.


below, it is normal 2) Set monitoring
(rpm) code to 16
Engine
speed

No. 2 throttle Monitoring DH Approx. 1,980 (command


signal code 16 value).
H Approx. 1,980 3) Operate
working mode
G Approx. 1,880 switch.

If the condition is within the range shown 1) Turn starting


in the table below, it is normal. switch ON.
2) Insert T-adapter.
Model selection 1 Between C17(5) and C16(3)(4) 20 – 30 V
Measure
voltage

Model Model selection 2 Between C17(13) and C16(3)(4) 20 – 30 V


selection C16
connector C17 Model selection 3 Between C17(6) and C16(3)(4) 20 – 30 V
Model selection 4 Between C17(14) and C16(3)(4) 20 – 30 V
Model selection 5 Between C17(7) and C16(3)(4) Max. 1 V

If the condition is within the range shown 1) Turn starting


in the table below, it is normal. switch ON.
Measure
voltage

2) Insert T-
S-NET C17 Between (4), (12) and chassis 4–8V adapter.

20-18 PC750, 800-6


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement


Judgment table
tem component No. method conditions
If the condition is within the range shown 1) Turn starting
in the table below, it is normal. switch ON.

Measure
voltage
2) Insert T-
Kerosene Standard mode
C17 Between (15) 20 – 28 V adapter.
mode
Kerosene mode and chassis 0–2V

If the condition is as shown in the table 1) Turn starting


below, it is normal switch ON.
Measure 2) Turn fuel
TVC solenoid Monitoring current G mode 540 ± 30 mA control dial to
valve (default code 13 MAX position.
setting) 3) Turn emer-
gency pump
drive switch
OFF.

If the condition is within the range shown 1) Turn starting


in the table below, it is normal. switch ON.
Measure
voltage

2) Insert T-
TVC solenoid C02 Between (18) and (11)(21) 0–1V adapter.
3) Turn fuel
control dial to
MAX position.

If the condition is within the range shown 1) Start engine.


in the table below, it is normal. 2) Turn swing lock
switch ON.
Pump controller system

When swing lever or 3) Turn swing


any work equipment holding brake
control lever is operated 20 – 30 V release switch
Measure
Controller

(solenoid ON : swing OFF.


voltage

Swing holding holding brake released) Between 4) Insert T-adapter.


C01
brake solenoid (3) and fl It is also
Approx. 10 sec after possible to
swing lever or all work (6), (12)
operate the lever
equipment control lever in small move-
0–3V
are placed at neutral ments (not
(solenoid OFF : swing enough for the
holding brake actuated) machine to
move).

If the condition is within the range shown 1) Start engine.


in the table below, it is normal. 2) Insert T-
adapter.
Travel speed switch at Hi 3) Turn fuel
(solenoid ON: travel
Measure

control dial to
voltage

20 – 30 V
Travel speed motor swash plate angle MAX position.
C01 at min.) Between
solenoid (9) and
Travel speed switch at Lo (6), (12)
(solenoid OFF: travel 0–3V
motor swash plate angle
at max.)

If the condition is within the range shown 1) Start engine.


in the table below, it is normal. 2) Insert T-
adapter.
When boom RAISE is 3) Operate boom
operated independently
Measure

lever to RAISE
voltage

Main 2-stage with machine push-up position.


C01 Between 20 – 30 V
relief solenoid switch at ON (solenoid (10) and fl It is also
ON) (6), (12) possible to
operate the lever
Machine push-up switch in small move-
at OFF (solenoid OFF) 0–3V
ments (not
enough for the
boom to move).

PC750, 800-6 20-19


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement


Judgment table
tem component No. method conditions
If the condition is within the range shown 1) Start engine.
in the table below, it is normal. 2) Insert T-

Measure
adapter.

voltage
Working mode DH mode
CO cancel C01 (solenoid ON) Between 20 – 30 V
solenoid (8) and
Working mode H mode or (6), (12) 0 – 3 V
G mode (solenoid OFF)

If the condition is within the range shown 1) Start engine.


in the table below, it is normal. 2) Insert T-
adapter.
When left and right travel
Measure
voltage

and work equipment are


Straight-travel operated at same time Between 20 – 30 V
solenoid C01
(solenoid ON) (2) and
(6), (12)
All levers at neutral
(solenoid OFF) 0–3V

If the condition is within the range shown 1) Start engine.


in the table below, it is normal. 2) Insert T-
Measure

adapter.
voltage

Swing priority Swing priority selector


Pump controller system

20 – 30 V
selector C01 switch ON (solenoid ON) Between
(5) and
solenoid Swing priority selector (6), (12) 0 – 3 V
switch OFF (solenoid OFF)
Controller

If the condition is within the range shown 1) Start engine.


in the table below, it is normal. 2) Insert T-
adapter.
Auto-deceleration
Measure
voltage

fl Operate lever
Auto-decelera- Between switch ON + all work 20 – 30 V slightly
C01 equipment levers at
tion signal (4) and (enough to
(6), (12) neutral turn PPC
Auto-deceleration pressure
switch OFF Max. 1 V
switch ON)

If the condition is within the range shown 1) Step light


in the table below, it is normal. switch ON.
Measure

2) Wait for at
voltage

Step light 20 – 30 V 1) least 1 minute


C01 Between (1) and (6)
drive relay after step light
0–3V 2) goes OFF.
3) Insert T-
adapter.

If the condition is within the range shown 1) Step light


in the table below, it is normal. switch ON.
Measure

Controller 2) Wait for at


voltage

power source 20 – 30 V 1) least 1 minute


C01 Between (7) and (6)
(when key after step light
OFF) 0–3V 2) goes OFF.
3) Insert T-
adapter.

20-20 PC750, 800-6


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement


Judgment table
tem component No. method conditions
If the condition is within the range shown 1) Step light
in the table below, it is normal. switch ON.

Measure
2) Wait for at

voltage
Step light 0–3V 1) least 1 minute
power source
Pump controller system

C01 Between (6) and C01(6) after step light


keeping relay 20 – 30 V 2) goes OFF.
3) Insert T-
Controller

adapter.

If the condition is within the range shown 1) Horn switch


in the table below, it is normal. ON.
2) Horn switch
Measure
voltage
fl 20 – 30 V 1) OFF.
Flash light C01 Between (11) and (6) 3) Start engine.
drive relay 0 – 3 V 2) 4) Insert T-
adapter.
fl Changes 0 V ↔ 20 – 30 V approx. every
0.35 sec.

If the condition is within the range shown 1) Turn starting


resistance

in the table below, it is normal. switch OFF.


Measure

V03 2) Disconnect
(male) Between (1) and (2) 20 – 60 Ω connector V03.
Between (2) and chassis Min. 1 MΩ
Machine push-up
solenoid valve
(Controller dose If the condition is within the range shown 1) Start engine.
not controlled) in the table below, it is normal. 2) Insert T-
Measure
voltage

adapter.
Machine push-up switch
V03 ON (solenoid ON) Between 20 – 30 V
(2) and
Machine push-up switch chassis 0–3V
OFF (solenoid OFF)

If the condition is as shown in the table 1) Turn starting


continuity

below, it is normal. switch OFF.


Measure
Others

Machine push-up M38 2) Disconnect


Between When switch is ON No continuity connector
switch (female) (1) and M38.
(2) When switch is OFF Continuity

If the condition is within the range shown 1) Turn starting


resistance

in the table below, it is normal. switch OFF.


Measure

V05 2) Disconnect
Machine push-up Between (1) and (2) 20 – 60 Ω connector V05.
solenoid (male)
Between (1)(2) and chassis Min. 1 MΩ

If the condition is within the range shown 1) Turn starting


resistance

in the table below, it is normal. switch OFF.


Measure

V09 (male)
Boom shockless (RAISE) 2) Disconnect
Between (1) and (2) 20 – 60 Ω connectors
solenoid V10 (male)
(LOWER) V09, V10.
Between (1)(2) and chassis Min. 1 MΩ

PC750, 800-6 20-21


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement


Judgment table
tem component No. method conditions
If the condition is as shown in the table 1) Start engine.
below, it is normal. 2) Insert T-
adapter.
Boom shockless switch

Measure
Boom shockless V09

voltage
solenoid valve ON (solenoid ON) , 20 – 30 V
(RAISE)
(Controller dose shockless mode release Between
V10 (2) and
not controlled) (LOWER) Boom shockless switch chassis
OFF (solenoid OFF) , 0–3V
Others

shockless mode

If the condition is as shown in the table 1) Turn starting


continuity
below, it is normal. switch OFF.
Measure

Machine push-up M33 2) Disconnect


Between When switch is ON No continuity connector
switch (male) (1) and M33.
(2) When switch is OFF Continuity

20-22 PC750, 800-6


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement


tem component No. method Judgment table conditions
If the condition is as shown in the table 1) Turn starting
below, it is normal. switch OFF.

continuity
Measure
2) Disconnect con-
Air cleaner clog- P11 Air cleaner normal Between Continuity nector P11.
ging sensor (male) (1) and
Air cleaner clogging (2) No continuity

If the condition is as shown in the table 1) Turn starting


below, it is normal. switch OFF.
resistance
Measure 2) Disconnect
Above LOW water level connectors
Engine water level P08 (male) in sub tank Max. 1 Ω
sensor P20 (male) P08, P20.
Below LOW water level 3) Insert T-
in sub tank Min. 1 MΩ adapter into
connector at
sensor end.

If the condition is as shown in the table 1) Turn starting


below, it is normal. switch ON.
Measure
voltage

2) Insert T-
Engine oil level OL Engine oil above adapter into
low level Between Max. 1 Ω
sensor (male) (1) and connector OL.
Engine oil below chassis
low level Min. 1 MΩ

If the condition is as shown in the table 1) Turn starting


Monitor system

below, it is normal switch OFF.


continuity
Measure

Hydraulic oil 2) Disconnect


temperature P10 Normal temperature (25°C) Continuity connector P10.
sensor (male) 3) Insert T-
Above 120°C No continuity adapter into
connector at
sensor end.

If the condition is as shown in the table 1) Turn starting


below, it is normal switch OFF.
2) Disconnect
Measure resistance

connector P06.
Raise 3) Drain fuel, then
float to Approx. 12 Ω
or below remove sen-
P06 stopper sor.
Fuel level sensor BLP00004
4) Insert T-
(male)
adapter
Lower fl Connect T-
float to Approx. 85 – adapter into
stopper 110 Ω the connector
BLP00005
and sensor
flange.

If the condition is as shown in the table 1) Turn starting


below, it is normal switch OFF.
Measure resistance

2) Disconnect
Raise connector P09.
Hydraulic oil level P09 float Max. 1 Ω 3) Drain oil, then
sensor (male) BLP00002 remove sen-
sor.
Lower 4) Insert T-
float Min. 1 MΩ adapter into
BLP00003
sensor.

PC750, 800-6 20-23


TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement


tem component No. method Judgment table conditions

Between When engine is running (1/2 throttle or above) 1) Start engine.

Measure
voltage
alternator → 27.5 – 29.5 V
Alternator terminal R fl If the battery is old, or after starting in cold
and areas, the voltage may not rise for some
chassis time.

If the condition is as shown in the table 1) Insert dummy


below, it is normal. resistance with
the starting
Position of Display level resistance (kΩ) switch OFF, or
gauge display (Controller input resistance) measure
Starting switch Starting switch resistance of
Measure resistance · Checking display
ON OFF the sensor.
2) Check the
Right All OFF – 0.646 display with
side
the starting
9 0.575 – 0.342 switch ON.
fl Do not use
Engine water high 8 3.156 – 3.708 engine water

temperature E12
(female) low-tempera-
sensor 7 3.422 – 3.900 ture sensor
Between

[ ]
Engine water signal for
position
Display

temperature (4) and (10) 6 3.600 – 4.349 engine tem-


gauge perature
5 4.015 – 5.122 gauge.
4 4.728 – 6.816

3 6.294 – 10.744
Monitor system

2 9.946 – 36.535
side
Left

1 33.725 –
flLevels 8 and 9 flash.

If the condition is as shown in the table 1) Insert dummy


below, it is normal. resistance with
the starting
Position of Display level resistance (kΩ) switch OFF, or
gauge display (Controller input resistance) measure
Starting switch Starting switch resistance of
Measure resistance · Checking display

ON OFF the sensor.


2) Check the
All OFF – 13.82 display with
Right
side

the starting
9 11.71 – 21.25 switch ON.
8 18.90 – 28.45

Fuel level C03


sensor (female) 7 25.82 – 31.85
Between
[Fuel level
]
position
Display

gauge (2) and (16) 6 29.18 – 39.91

5 37.00 – 44.60

4 41.77 – 55.14

3 50.42 – 77.07

2 72.98 – 691.50
side
Left

1 63.800 –
flLevel 1 flashes.

20-24 PC750, 800-6


TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Check or measurement item Symbol Part No. Part Name Remarks


Engine speed A 799-203-8001 Multi-tachometer Digital display L: 60 – 2,000 rpm
H: 60 – 19,999 rpm
Water, oil and exhaust gas
temperature B 799-101-1502 Digital temperature gauge –99.9 to +1,299°C
Pressure 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester gauge: {25, 60, 400, 600 kg/cm2}
1
790-261-1203 Digital hydraulic tester

790-101-5160 • Nipple PT1/8


2 799-101-5220 Nipple 10 x 1.25
07002-11023 O-ring

790-261-1311 • Adapter Male, female both 14 x 1.5 (female PT 1/8)


Oil pressure C
790-261-1321 • Adapter Male, female both 18 x 1.5 (female PT 1/8)
3
790-261-1331 • Adapter Male, female both 22 x 1.5 (female PT 1/8)
790-261-1340 • Adapter Male, female both 10 x 1.25 (female PT 1/8)
4 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}
5 799-401-2701 Differential pressure gauge
6 21T-98-11490 Coupling assembly Remaining pressure and air bleeding
795-502-1590 Gauge assembly 6.9 MPa {70 kg/cm2}
Compression pressure D 795-471-1310 Adapter For SA6D140E-3 engine
6217-71-6110 Gasket
Blow-by pressure E 799-201-1504 Blow-by checker 0 – 49 MPa {0 – 500 mmH2O}
Inlet air pressure
(boost pressure) F 799-201-2202 Boost gauge kit –101 – 199.9kPa (–760 – 1,500mmHg}
Commercially SA6D140E-3 engine
Valve clearance G available Filler gauge Intake : 0.35mm, exhaust : 0.57mm
1 799-201-9000 Handy smoke checker Dirtiness 0 – 70% (with standard
Exhaust gas color H color)
Commercially
2 available Smoke meter (Dirtiness % x 1/1 = Bosch scale)

79A-264-0021 Push-pull scale 0 – 294N {0 – 30 kg}


Operating effort I
79A-264-0091 Push-pull scale 0 – 490N {0 – 50 kg}
Commercially
Stroke and hydraulic drift K available Scale
Commercially
Work equipment speed L available Stop watch
Commercially
Voltage and resistance values M available Tester

PC750, 800-6 20-25


TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Check or measurement item Symbol Part No. Part Name Remarks


1 799-601-8000 T-adapter kit

2 799-601-9000 T-adapter kit HD30, T-adapter for DT, box


3 799-601-7370 Adapter For 6-pin relay
4 799-601-7050 Adapter SWP-6P
Troubleshooting of wiring
harnesses and sensors N 5 799-601-7080 Adapter M-1P
6 799-601-7310 Adapter SWP-12P
7 799-601-7320 Adapter SWP-16P
8 799-601-7340 Adapter M-16P
9 799-601-7540 Adapter 070-18P
Measuring wear of sprocket P 796-627-1110 Wear gauge

20-26 PC750, 800-6


TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)

MEASURING AIR SUPPLY


PRESSURE (BOOST PRESSURE)
¤ When removing or installing the measuring equip-
ment, be careful not to touch any high tempera-
ture parts.
fl Measure the air supply pressure under the fol-
lowing conditions.
• Coolant temperature: Within operating range
• Hydraulic oil temperature : 45 – 55°C

1. Remove air supply pressure measurement plug


(1).

2. Install nipple q of boost gauge kit F, then con-


nect to the boost gauge kit.

3. Run the engine at a mid-range speed or above,


and bleed the oil from inside the hose.
fl Insert the connection of the pressure gauge
and hose about half way, and repeatedly
open the self-seal portion at the hose end to
bleed the oil.
fl If Pm kit is available, the air bleed coupling
(790-261-1130) inside the kit can also be used.

4. Set the working mode switch to DH mode and


turn the heavy lift switch ON.

5. Run the engine at high idling and measure the


air supply pressure when the boom RAISE cir-
cuit is relieved.

6. After completing the measurement, remove the


measuring equipment and set to the original
condition.

20-28 PC750, 800-6


TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE

MEASURING EXHAUST
TEMPERATURE
¤ Wait for the temperature of the exhaust mani-
fold to go down before removing or installing
the measuring equipment.
fl Measure the exhaust temperature under the fol-
lowing conditions.
• Coolant temperature: Within operating range
• Hydraulic oil temperature : 45 – 55°C

1. Remove exhaust temperature measurement plug


(1).

2. Install sensor q of digital temperature gauge B,


then connect to the digital temperature gauge.
fl Clamp the wiring harness of the temperature
gauge so that it does not touch any high
temperature part during the measurement.

3. Run the engine at high idling and measure the


maximum temperature during actual operation.

4. After completing the measurement, remove the


measuring equipment and set to the original
condition.

PC750, 800-6 20-29


TESTING AND ADJUSTING MEASURING EXHAUST COLOR

MEASURING EXHAUST COLOR


• When measuring in the field where there is no
air or electric power supply, use Handy Smoke
Checker H1; when recording formal data, use
Smoke Meter H2.
fl Raise the coolant temperature to the operat-
ing range before measuring.
¤ Be careful not to touch any hot parts when re-
moving or installing the measuring tools.

1. Measuring with Handy Smoke Checker H1


1) Install filter paper to Handy Smoke Checker
H1.
2) Insert the exhaust gas suction port into the
exhaust pipe, accelerate the engine suddenly,
and operate the handle of Handy Smoke
Checker H1 at the same time to collect the
exhaust gas on the filter paper.
3) Remove the filter paper and compare it with
the scale supplied to judge the condition.

2. Measuring with Smoke Meter H2


1) Insert the probe q of Smoke Meter H2 into
the outlet port of the exhaust pipe, and
tighten the clip to secure it to the exhaust
pipe.
2) Connect the air hose and the socket of the
probe hose and accelerator switch to Smoke
Meter H2.
fl Keep the pressure of the air supply be-
low 1.5 MPa {15 kg/cm2}.
3) Connect the power cord to the AC socket.
fl When connecting the cord, check that
the power switch of Smoke Meter H2 is
OFF.
4) Loosen the cap nut of the suction pump,
and fit the filter paper.
fl Fit the filter paper securely so that the
exhaust gas cannot leak.
5) Turn the power switch of Smoke Meter H2
ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal of Smoke Meter H2 at
the same time to collect the exhaust gas
color on the filter.
7) Place the filter paper used to catch the ex-
haust gas color on top of at least 10 sheets
of unused filter paper inside the filter paper
holder, and read the value shown.

20-30 PC750, 800-6


TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE
CLEARANCE
1. Remove cylinder head cover (1).

2. Rotate the crankshaft in the normal direction to


align [1.6] line a on the damper with pointer (2),
and set the No. 1 cylinder compression to top
dead center.
fl Use the hexagonal portion at the tip of the
water pump drive shaft to rotate the crank-
shaft.
fl At compression top dead center, the rocker
arm of the valve can be moved by hand the
amount of the clearance. If the rocker arm
does not move, the cylinder is not at com-
pression top dead center, so rotate one more
turn.

3. Insert feeler gauge G in clearance b between


rocker arm (3) and crosshead (4), and turn ad-
justment screw (5) to adjust the valve clearance.
fl With feeler gauge G inserted, turn the ad-
justment screw and adjust until the clear-
ance is a sliding fit.
fl Valve clearance Intake valve : 0.35 mm
Exhaust valve : 0.57 mm

4. Tighten locknut (6) to hold adjustment screw (5)


in position.
3 Locknut : 53.0 – 64.7 Nm {5.4 – 6.6 kgm}
fl After tightening the locknut, check the valve
clearance again.

5. Rotate the crankshaft 120° each time in the nor-


mal direction and repeat Steps 2 – 4 to adjust
the valve clearance of each cylinder according
to the firing order.
fl Firing order : 1–5–3–6–2–4

6. After completing the adjustment, set to the origi-


nal condition.
3 Mounting bolt of cylinder head cover :
29.4 – 34.3 Nm {3.0 – 3.5 kgm}

PC750, 800-6 20-31


MEASURING BLOW-BY PRESSURE
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

MEASURING BLOW-BY
PRESSURE
fl Measure the blow-by pressure under the follow-
ing conditions.
• Coolant temperature: Within operating range
• Hydraulic oil temperature: 50 – 80°C

1. Install the nozzle of blow-by checker E to blow-


by hose (1).

2. Connect the nozzle and gauge with the hose.

3. Run the engine at near the rated output and


read the pressure on the gauge.
fl Near rated output
• Set to the D.H mode, relieve the arm IN
circuit, and measure the blow-by pressure.
fl Measure the blow-by pressure at the point
where the gauge indicator remains steady.

MEASURING COMPRESSION
PRESSURE
fl For details of the method for measuring the com-
pression pressure, see the shop manual for the
140-3 Series Engine.

20-32 PC750, 800-6


TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL


PRESSURE
fl Measure the engine oil pressure under the fol-
lowing conditions.
• Coolant temperature: Within operating range

1. Remove oil low-pressure switch (1) or oil high-


pressure switch (2).
fl After removing the switch, wind the wiring
harness with tape to prevent it from contact-
ing the cylinder block.

2. Install nipple q of oil pressure gauge C2, then


connect to the oil pressure gauge.

3. Start the engine and measure the oil pressure


with the engine at low idling and high idling.

4. 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}

PC750, 800-6 20-33


HANDLING EQUIPMENT IN FUEL CIRCUIT
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN FUEL SYSTEM

HANDLING EQUIPMENT IN RELEASING REMAINING


FUEL CIRCUIT PRESSURE IN FUEL SYSTEM
fl Precautions for inspection and maintenance fl When the engine is running, pressure is gen-
of fuel system erated in both the low-pressure circuit and
The common rail type fuel injection system high-pressure circuit of the fuel line.
is constructed of more precise components Low-pressure circuit: Feed pump – fuel filter
than the conventional fuel injection pump – fuel supply pump
and nozzle, so problems may occur if dirt or High-pressure circuit:Fuel supply pump –
dust get in. common rail – fuel in-
When carrying out inspection and mainte- jector
nance of the fuel system, pay more atten- fl For both the low-pressure circuit and high-
tion than usual to prevent dirt or dust from pressure circuit, the pressure automatically
getting in. If there is any dirt stuck to any goes down to a safe level 30 seconds after
part, use clean fuel to wash it off completely. the engine is stopped.
fl Precautions when replacing fuel filter car- fl The remaining pressure in the fuel system
tridge must be completely released before carry-
Always use a genuine Komatsu part for the ing out inspection of the fuel system or re-
fuel filter cartridge. moval or installation of the equipment. Al-
The common rail type fuel injection system ways follow the following precautions when
is constructed of more precise components carrying out the operation.
than the conventional fuel injection pump ¤ When inspecting the fuel line or removing
and nozzle, so a special filter with high effi- or installing equipment, wait for at least 30
ciency filtering ability is used to prevent dirt seconds after the engine is stopped, and re-
or dust from getting in. lease the remaining pressure in the fuel sys-
For this reason, if any filter is used as a tem before starting the operation. (There is
substitute for the genuine filter, there is dan- still pressure remaining in the circuit, so do
ger that problems will occur with the fuel not start operations immediately after the
system. To prevent this, never use such fil- engine is stopped).
ters.

20-34 PC750, 800-6


TESTING AND ADJUSTING MEASURING FUEL PRESSURE

MEASURING FUEL PRESSURE


fl Measure the fuel pressure only for the low-pres-
sure circuit between the feed pump – fuel filter –
fuel supply pump.
¤ The high-pressure circuit between the fuel sup-
ply pump – common rail – fuel injector is under
extremely high pressure, so it cannot be mea-
sured.

1. Remove fuel pressure measurement plug (1).

2. Fit nipple q of oil pressure gauge C2, then con-


nect to the oil pressure gauge.

3. Start the engine and measure the fuel pressure


at high idling.
fl For details of the standard value, see
Troubleshooting of Engine Controller Sys-
tem (E Mode).

4. After completing the measurement, remove the


measuring equipment and set to the original
condition.

PC750, 800-6 20-35


TESTING AND ADJUSTING REDUCED CYLINDER MODE OPERATION FOR ENGINE

REDUCED CYLINDER MODE OPERATION FOR ENGINE


fl Reduced cylinder mode operation for the engine means setting the fuel injectors of a single
cylinder or multiple cylinders electrically to the NO INJECTION condition to run the engine on a
reduced number of cylinders. The reduced cylinder mode operation is used when it is thought that
one of the engine cylinders is not giving normal output (combustion). It is a method to determine
which cylinder is not operating normally (for details, see the shop manual for the 140-3 Series
Engine).
fl The reduced cylinder mode operation is carried out by using the reduced cylinder mode operation
setting function on the monitor panel.
For details of the functions of the monitor panel, see the TROUBLESHOOTING, Monitor panel
display and special functions.

1. Turn the starting switch ON.

2. Keep time switch (1), R.H. travel speed switch


(2), and R.H. working mode switch (3) pressed
at the same time for at least 2.5 seconds.
fl The monitor panel will switch to the reduced
cylinder mode operation, time display (4) will
show the engine speed, and service meter
display (5) will show the cylinder number.
fl The engine speed is displayed in units of 10
rpm.

3. Start the engine, then measure the low idling


speed and high idling speed.
fl When carrying out the reduced cylinder
mode operation, note down the engine speed
when the reduced cylinder mode operation
is not used in order to use it as the standard
for judgment.

4. Use the following procedure to set the cylinder


for the reduced cylinder mode operation.
fl It is possible to set the reduced cylinder
mode operation for a single cylinder or mul-
tiple cylinders.
1) Keep time mode switch (1) pressed, operate
working mode switches (3) and (6), and se-
lect the number of the cylinder for the re-
duced cylinder mode operation.
fl The number for the selected cylinder
flashes on the display.
2) Keep time mode switch (1) pressed and op-
erate heavy lift switch (7) to set the reduced
cylinder mode operation.
fl When the reduced cylinder mode opera-
tion is set, the liquid crystal segment for
the cylinder number changes the display
gradually from a flashing number, and
finally two segments (top and bottom)
light up.

20-36 PC750, 800-6


TESTING AND ADJUSTING REDUCED CYLINDER MODE OPERATION FOR ENGINE

fl During the time that the cylinder num-


ber changes the display gradually from
a flashing number to the lighted up top
and bottom segments, the monitor panel
and engine controller are sending and
receiving signals, so check that the
change to the top and bottom segments
lighting up has completely finished be-
fore going on to the next operation.
3) When multiple cylinders are to be set, re-
peat Steps 1) and 2).

5. Measure the low idling speed and high idling


speed during reduced cylinder mode operation.
fl Compare the engine speed during reduced
cylinder mode operation with the engine
speed noted down in Step 3 (when the re-
duced cylinder mode operation was not be-
ing used). Determine the abnormal cylinder
from this.

6. Use the following procedure to cancel the cylin-


der set for the reduced cylinder mode opera-
tion.
1) Keep time mode switch (1) pressed, operate
working mode switches (3) and (6), and se-
lect the segment of the cylinder to be can-
celed for the reduced cylinder mode opera-
tion.
fl The two top and bottom segments for
the selected cylinder flash on the dis-
play.
2) Keep time mode switch (1) pressed and op-
erate heavy lift switch (7) to cancel the re-
duced cylinder mode operation.
fl When the reduced cylinder mode opera-
tion is canceled, the liquid crystal seg-
ment for the cylinder number changes
the display gradually from the two flash-
ing segments (top and bottom) and fi-
nally become a flashing number.
fl During the time that the cylinder num-
ber changes the display gradually from
two flashing top and bottom segments
to the flashing number, the monitor panel
and engine controller are sending and
receiving signals, so check that the
change to the flashing number has com-
pletely finished before going on to the
next operation.
3) When multiple cylinders have been set, re-
peat Steps 1) and 2).

7. After completing the measurement, keep time


switch (1), R.H. travel speed switch (2), and R.H.
working mode switch (3) pressed at the same
time for at least 2.5 seconds to finish the re-
duced cylinder mode.

PC750, 800-6 20-37


TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT

BLEEDING AIR FROM FUEL CIRCUIT

fl Bleed the air as follows if the engine has run


out of fuel or the fuel circuit equipment has
been removed and installed.

1. Remove fuel filter (1), fill with fuel, then install


again.
fl When filling, use clean fuel and be careful
not to let dirt get in.
fl Add fuel through inlet port portion a (8
places) of the filter. Portion b is the outlet
port (clean side) after the fuel has been fil-
tered, so never add fuel from here.
fl If clean fuel is not available, do not remove
the filter. Operate the priming pump to fill
the filter with fuel.

20-38 PC750, 800-6


TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT

2. Remove air bleed plug (2) of the fuel filter and


operate priming pump (3).
fl Continue operating the priming pump until
fuel flows out from the plug hole. When fuel
comes out, install the plug.
3 Air bleed plug :
7.8 – 9.8 Nm {0.8 – 1.0 kgm}

3. Loosen air bleeder (4) of the fuel supply pump


and operate priming pump (3) 90 to 100 times.
fl Continue operating the priming pump until
fuel flows out from the bleeder. When fuel
comes out, tighten the bleeder, then operate
several tens of times until the priming pump
becomes stiff.
3 Air bleed plug :
4.9 – 6.9 Nm {0.5 – 0.7 kgm}

4. Crank the engine with the starting motor and


start the engine.
fl When the high-pressure circuit is cranked
with the engine, the air is automatically bled.
fl If the engine does not start, the air has prob-
ably been not properly bled from the low-
pressure circuit, so repeat the procedure
from Step 2.

PC750, 800-6 20-39


TESTING AND ADJUSTING CHECKING FOR LEAKAGE IN FUEL CIRCUIT

CHECKING FOR LEAKAGE IN


FUEL CIRCUIT
¤ With the fuel system, the high-pressure cir- 8. Start the engine, run it at high idling, then
cuit is under extremely high pressure, so if apply load to the engine.
fuel leaks when the engine is running, there fl If this inspection is carried out with the
is danger of fire. engine mounted on the machine, stall the
Check for fuel leakage as follows when check- torque converter or relieve the hydraulic
ing the fuel circuit or when equipment has pump.
been removed and installed.
fl To make it easier to check for fuel leakage, 9. Check the fuel piping and equipment for fuel
wipe the engine itself and the surrounding leakage.
area clean and remove all oil and grease fl Check the high-pressure circuit for fuel
before starting the inspection. leakage, particularly at the places sprayed
with color checker.
1. Spray the fuel supply pump, common rail, fl If there is fuel leakage, carry out repairs,
fuel injector, and high-pressure piping con- then repeat the check from Step 2.
nections with a color checker (developing fl If no fuel leakage is found, the check is
solution). complete.

2. Start the engine, run it at under 1000 rpm,


and when the speed stabilizes, stop the en-
gine.

3. Check the fuel piping and equipment for fuel


leakage.
fl Check the high-pressure circuit for fuel
leakage, particularly at the places sprayed
with color checker.
fl If there is fuel leakage, carry out repairs,
then repeat the check from Step 2.

4. Start the engine and run it at low idling.

5. Check the fuel piping and equipment for fuel


leakage.
fl Check the high-pressure circuit for fuel
leakage, particularly at the places sprayed
with color checker.
fl If there is fuel leakage, carry out repairs,
then repeat the check from Step 2.

6. Start the engine and run it at high idling.

7. Check the fuel piping and equipment for fuel


leakage.
fl Check the high-pressure circuit for fuel
leakage, particularly at the places sprayed
with color checker.
fl If there is fuel leakage, carry out repairs,
then repeat the check from Step 2.

20-40 PC750, 800-6


TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

TESTING AND ADJUSTING


ALTERNATOR BELT TENSION
1. Inspecting
Measure deflection a when the belt is pressed
with a finger at a point midway between the
alternator pulley and drive pulley.
fl Pushing force:
Approx. 98 Nm {approx. 10 kg}
fl Deflection (one belt): 10 – 15 mm

2. Adjusting
fl If the deflection is not within the specified
range, adjust as follows.
1) Loosen 2 mounting bolts of alternator (1)
and 1 lock bolt of the bar.
2) Loosen locknut (2), move alternator (1) with
adjustment nut (3), and adjust the tension of
belt (4).
fl Deflection (one belt): 10 – 15 mm
3) Tighten locknut (2).
4) Tighten 2 mounting bolts of alternator (1)
and 1 lock bolt of the bar.
fl After adjusting, check the belt tension again.

PC750, 800-6 20-41


TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING FAN BELT TENSION

1. Testing
There is no need to inspect the fan belt tension
until the belt is replaced.

2. Adjusting
1) Install 2 belts (1).
fl Loosen the stopper bolt when installing
the belts.
2) Tighten stopper bolt (2) until it contacts
bracket (3).
3) Tighten stopper bolt (2) a further 2 turns
and secure in position with locknut (4).
3 Locknut :
245.0 – 308.7 Nm {25.0 – 31.5 kgm}

20-42 PC750, 800-6


TESTING AND ADJUSTING AIR CONDITIONER
TESTING AND ADJUSTING COMPRESSOR DRIVE BELT TENSION

TESTING AND ADJUSTING AIR


CONDITIONER COMPRESSOR
DRIVE BELT TENSION

Testing
1. Remove the bolt, then remove cover (1).

2. Check deflection b of the belt when it is pressed


at a point midway between the drive pulley and
the air conditioner compressor pulley with a fin-
ger force of approx. 58.8 N {approx. 6 kg}.
fl Standard deflection b: approx. 10 – 15 mm

Adjusting
fl If the deflection of the belt is not within the
standard range, adjust as follows.
1. Loosen compressor mounting bolt (2), lock bolt
(3), and locknut (4) of the belt tension adjust-
ment bolt.
b
2. Turn adjustment nut (5) to move compressor (6)
and adjust the tension of belt (7), then tighten
bolts (3) and (2) and locknut (4).

PC750, 800-6 20-43


TESTING AND ADJUSTING HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT

HANDLING ENGINE CONTROL-


LER HIGH VOLTAGE CIRCUIT
¤ With the engine controller, a high-voltage cir-
cuit (110 – 130V) is used for the fuel injector
drive.
As a result, a high-voltage circuit is connected
to the wiring harness and connector from the
engine controller to the fuel injector.
fl Normally, high voltage is output from the en-
gine controller to the fuel injector only when the
engine is running. When the engine is stopped,
the output stops.
¤ If the high-voltage circuit is touched directly,
there is danger of elec-trocution, so observe the
following precautions when carrying out inspec-
tion.
1. The connectors, including those for the high volt-
age circuit, are as follows.
• Engine controller connector: CN7, CN8
• Intermediate connector: E21
• Injector connector:CN1, CN2, CN3, CN4, CN5,
CN6
• Terminal at head of injector (inside head
cover)
2. Always turn the starting switch OFF before dis-
connecting or connecting the applicable connec-
tor.
3. When a T-adapter has been inserted or con-
nected to the applicable connector to carry out
troubleshooting, never start the engine.
fl If the starting switch is operated, operate it
only to OFF or ON. Never turn it to the START
position.

20-44 PC750, 800-6


TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR

ADJUSTING ENGINE SPEED


SENSOR
fl Adjust the engine speed sensor for the engine
controller as follows.
fl The engine G rotation sensor and engine Ne
rotation sensor for the engine controller cannot
be adjusted.

1. Screw in sensor (1) until the tip contacts the tip


of the tooth of fly-wheel ring gear (2).
fl Check that there is no damage or metal pow-
der on the tip of the sensor when installing.
2 Thread : Hydraulic sealant

2. Turn sensor (1) back 1/2 – 2/3 turns.


fl This makes a clearance 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}

PC750, 800-6 20-45


TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK
TESTING AND ADJUSTING EQUIPMENT, SWING, TRAVEL CIRCUIT

TESTING AND ADJUSTING


HYDRAULIC PRESSURE IN
WORK EQUIPMENT, SWING,
TRAVEL CIRCUIT
Measuring
1. Measuring at normal pressure
fl Oil temperature when measuring: 45 – 55˚C
¤ Lower the work equipment to the ground
and stop the engine. Operate the control le-
vers several times to release the remaining
pressure in the hydraulic piping. Loosen the
oil filler cap slowly to release the pressure
inside the hydraulic tank.
Then put the safety lock lever in the LOCK
position.
1) Install oil pressure gauge C1 (58.8 MPa {600
kg/cm2}) to quick coupler (1) or (2) (for R.H.
4-spool valve) and (3) or (4) (for L.H. 5-spool
valve).
2) Start the engine, set to the D.H mode, then
measure the main relief pressure with the
engine at full throttle.
• Set the actuator to be measured to the
following condition.
i) For the work equipment, operate the
respective cylinder to the end of its
stroke.
ii) For the swing, turn the swing lock
switch ON.
iii) For the travel, fit block q between
the sprocket and the frame to lock
the track shoe, then measure one
side at a time.

2. Measuring when pressure rises


1) When main relief valve pressure rises
i) Turn the heavy-lift switch ON.
ii) Relieve the boom RAISE circuit and mea-
sure the oil pressure.
2) When safety valve pressure at boom LOWER
end rises
i) Turn the machine push-up switch ON.
ii) Relieve the boom LOWER circuit and mea-
sure the oil pressure.
fl The set pressure when the pressure
rises is higher than the main relief
set pressure, so if the measurement
is the main relief pressure of 31.4
MPa {320 kg/cm2}, the situation is
normal.
fl If the pressure does not rise, the pres-
sure is 14.7 MPa {150 kg/cm2} (crack-
ing pressure), so this pressure is
measured.

20-46 PC750, 800-6


TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK
TESTING AND ADJUSTING EQUIPMENT, SWING, TRAVEL CIRCUIT

Adjusting
1. Main relief valve of left and right control valves
• (5): Main relief valve for L.H. 5-spool control
valve
• (6): Main relief valve for R.H. 4-spool control
valve
1) Adjusting high-pressure setting
i) Loosen locknut (7), then turn holder (8)
to adjust.
fl Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCK-
WISE.
To DECREASE pressure, turn COUN-
TERCLOCKWISE.
fl Amount of adjustment for one turn
of holder:
Approx. 21.78 MPa (222 kg/cm2}
3 Locknut :
107.8 ± 14.7 Nm {11 ± 1.5 kgm}
fl When the high-pressure setting is
changed, the low-pressure setting
will also change, so adjust the low-
pressure setting also.

2) Adjusting low-pressure setting


i) Loosen locknut (9).
fl Check that elbow (10) moves.
ii) Loosen locknut (11), then turn holder (12)
to adjust.
fl Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCK-
WISE.
To DECREASE pressure, turn COUN-
TERCLOCKWISE.
fl Amount of adjustment for one turn
of holder:
Approx. 21.78 MPa (222 kg/cm2}
3 Locknut :
85.75 ± 7.35 Nm {8.75 ± 0.75 kgm}
fl After completion of adjustment, repeat
the procedure in Item 1 to check the set
pressure again.

PC750, 800-6 20-47


TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK
TESTING AND ADJUSTING EQUIPMENT, SWING, TRAVEL CIRCUIT

3. Swing motor safety valve


• (1): For front swing motor
• (2): For rear swing motor
1) Remove cap (3).
2) Loosen locknut (5), then turn sleeve nut (6)
to adjust.
fl Carry out the adjustment with the valve
assembly installed to the motor.
fl Turn the adjustment screw to adjust as
follows.
• To INCREASE pressure, turn CLOCK-
WISE.
• To DECREASE pressure, turn COUN-
TERCLOCKWISE.
fl Amount of adjustment for one turn of
adjustment screw:
Approx. 3.6 MPa {37 kg/cm2}
3 Locknut :
166.5 ± 19.5 Nm {17 ± 2 kgm}

20-48 PC750, 800-6


TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE

TESTING AND ADJUSTING


CONTROL PUMP CIRCUIT OIL
PRESSURE
Measuring
fl Oil temperature when measuring: 45 – 55°C
1. Remove pressure pick-up plug (Thread
dia.=10mm, Pitch=1.25mm), and install oil pres-
sure gauge C1 (5.88 MPa {60 kg/cm2}).

2. Start the engine and measure with the engine at


full throttle.
fl When testing for internal leakage of the
equipment in the control circuit, use the parts
given below to shut off the circuit for the
following sections when measuring the re-
lief pressure.
Section of hydraulic Component that
No. circuit shut off can be checked

1 Piston pump inlet port Piston pump

Solenoid valve
2 Solenoid valve
inlet port
L.H. PPC valve
3 L.H. PPC valve
inlet port
Travel PPC valve
4 Travel PPC valve
inlet port
R.H. PPC valve
5 R.H. PPC valve
inlet port

fl Items No. 2 and below can be checked if the


equipment in the previous number is nor-
mal.
fl Use the following parts to shut off the cir-
cuit.
• For elbow
Sleeve nut : 07221-20315, 07222-00422
Plug : 07222-00312, 07222-00414
• For hose
Plug : 07376-50315, 07376-50422

PC750, 800-6 20-49


TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE

Adjusting
1. Remove cap (2).

2. Loosen locknut (3) and turn adjustment screw


(4) to adjust.
fl Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCKWISE
• To DECREASE pressure, turn COUNTER-
CLOCKWISE
3 Locknut : 9.8 Nm {1 kgm}
fl After completion of adjustment, repeat the
procedure in “Measuring” Item to check the
set pressure again.

20-50 PC750, 800-6


TESTING AND ADJUSTING TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE

TESTING AND ADJUSTING


PISTON PUMP CONTROL
PRESSURE
1. TVC valve output pressure
Measuring
fl Oil temperature when measuring: 45 – 55˚C
fl Measure the control pump relief pressure
first and check that it is normal.
fl The TVC valve output pressure varies ac-
cording to the average for the pump dis-
charge pressure ( P1+P2 = Average pres-
2
sure), so always adjust the main relief pres-
sure to the set pressure before measuring.
1) Remove pressure pickup plug (1) (Thread
dia.=10mm, Pitch=1.25mm) of the NC valve
at the No. 1 pump front end, then install
nipple 1 and oil pressure gauge C1 (5.88
MPa {60 kg/cm2}).
2) Start the engine, set to the D.H mode, run
the engine at full throttle, and measure the
output pressure at 2-pump relief (No. 1 pump
+ No. 2 pump).

Adjusting
fl If the result of the measurement shows that the
pressure is not within the standard value, adjust
as follows.
1) Loosen locknut (2).
2) Turn adjustment screw (3) to adjust.
fl If the adjustment screw is stiff and it is turned
by force, the tip may be damaged, so in this
case, remove the TVC valve assembly, then
remove the cover assembly and apply lubri-
cant to the screw portion before moving it.
3) Turn the adjustment screw to adjust as follows.
To INCREASE pressure, turn CLOCKWISE.
To DECREASE pressure, turn COUNTERCLOCK-
WISE.
fl Amount of adjustment for one turn of holder:
Approx. 0.34 MPa {3.5 kg/cm2}
3 Locknut :
7.84 ± 1.96 Nm {0.8 ± 0.2 kgm}
fl After completion of adjusting the adjustment
screw, repeat the procedure in Item 1 to
check the output pressure again.

PC750, 800-6 20-51


TESTING AND ADJUSTING TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE

2. Output pressure of CO valve and NC valve


• The output pressure of the NC valve goes to the
servo valve and controls the amount of oil dis-
charged from the piston pump.
The oil flows as follows: TVC valve → CO valve
→ NC valve → servo valve. The output pressure
varies as follows according to the operation of
the control lever for work equipment.
1) Control levers at neutral
Because of the differential pressure of the
jet sensor, the NC valve is actuated and the
output pressure drops below 0.54 MPa {5.5
kg/cm2}.
(The pump discharge becomes the mini-
mum.)
2) Hydraulic cylinder relieved
The CO valve moves and reduces the pres-
sure below 0.54 MPa {5.5 kg/cm2} before the
oil enters the NC valve. The NC valve sup-
plies the oil at this pressure to the servo
valve.
(The pump discharge amount in this case is
also the minimum.)
3) Work equipment, swing, travel operated
The output pressure of the TVC valve is not
influenced by the CO valve or the NC valve,
and supplies oil as it is to the servo valve.
(The pump discharge amount varies from
the maximum to the point where the CO
valve is actuated.)
4) CO cancel operated
In the D.H mode, the CO valve is not actu-
ated even near the relief pressure. There-
fore, in the same way as in Item 3), the
output pressure of the TVC valve is supplied
as it is to the servo valve.

Measuring
fl Oil temperature when measuring: 45 – 55˚C
• Remove pressure pickup plug (4) or (5) (Thread
dia.=10mm, Pitch=1.25mm), then install oil pres-
sure gauge C1 (5.88 MPa {60 kg/cm2}).
• Plug (4): For front pump (on bottom of No. 1
pump)
• Plug (5): For rear pump (on bottom of No. 1
pump)
fl The plugs are under the body of the servo
valve.

20-52 PC750, 800-6


TESTING AND ADJUSTING TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE

1) Oil pressure when NC valve is actuated


i) NC valve for No. 1 pump
Start the engine, set to the D.H mode, run
the engine at full throttle, and measure the
oil pressure when all the control levers are
at neutral.
fl Turn the auto deceleration switch OFF.
fl If the output pressure is more than 0.54 MPa
{5.5 kg/cm2}, measure the differential pres-
sure of the jet sensor.

2) Oil pressure when CO valve is actuated


Measure at the same time as measuring the
TVC valve output pressure.
i) No. 1 pump, No. 2 pump
Run the engine at full throttle, set to the H
mode, and measure the oil pressure when
any of the boom (except LOWER), arm, or
bucket circuits are relieved.

3) Oil pressure when CO valve and NC valve are


not actuated
i) When CO valve is not actuated
Set to the D.H mode, run the engine at full
throttle, and relieve the circuit from the arm
OUT end at the end of the IN stroke (at CO
cancel).
fl Measure from the beginning of the op-
eration to the point of relief.
ii) When NC valve is not actuated
Set to D.H mode, run the engine at full throt-
tle, and operate the travel to rotate the track
under no load.
fl Always operate the lever fully to the end
of its travel.
¤ When measuring with the tracks rotating un-
der no load, check carefully that the sur-
rounding area is safe.
fl When measuring the TVC valve output pres-
sure at the same time, if the difference is
large (0.1 MPa {1 kg/cm2} or more), the op-
eration of the CO valve or NC valve is prob-
ably defective.

PC750, 800-6 20-53


TESTING AND ADJUSTING TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE

Adjusting
1) CO valve
fl If the CO valve set pressure is high, the dis-
charge amount is not reduced at relief, so
the relief pressure becomes higher. For this
reason, always adjust to the set pressure.
1) Loosen locknut (7), then turn adjustment
screw (8) to adjust.
fl Front and rear (2 places)
fl Turn the adjustment screw to adjust as
follows.
To INCREASE pressure, turn CLOCK-
WISE.
To DECREASE pressure, turn COUNTER-
CLOCKWISE.
fl Amount of adjustment for one turn of
holder: Approx. 4.05 MPa {41.25 kg/cm2}
(but pump discharge pressure)
fl If the oil pressure does not go down even
when the adjustment screw is turned,
there is probably a defect inside the CO
valve.
3 Locknut :
7.84 ± 1.96 Nm {0.8 ± 0.2 kgm}
ii) After completion of adjusting the adjustment
screw, repeat the procedure in “Measuring”
Item 1 to check the set pressure again.

2) NC valve
fl The NC valve is actuated by the differential
pressure of the jet sensor, so always check
that the differential pressure of the jet sen-
sor is normal before adjusting.
1) Loosen locknut (9), then turn adjustment
screw (10) to adjust.
fl Front and rear (2 places)
fl Turn the adjustment screw to adjust as
follows.
To INCREASE pressure, turn CLOCK-
WISE.
To DECREASE pressure, turn COUNTER-
CLOCKWISE.
fl Amount of adjustment for one turn of
holder: Approx. 0.39 MPa (4 kg/cm2}
3 Locknut :
7.84 ± 1.96 Nm {0.8 ± 0.2 kgm}

20-54 PC750, 800-6


TESTING AND ADJUSTING TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE

3. Differential pressure of jet sensor


High pressure and low pressure (high pressure
– low pressure = differential pressure) is formed
at the outlet port of the control valves, and this
differential pressure controls the NC valve.
The differential pressure is at the maximum
when the control levers are at neutral, and at
the minimum when the control levers are oper-
ated fully.

Measuring
¤ Release the pressure inside the hydraulic tank.
fl Oil temperature when measuring: 45 – 55°C
1) Disconnect pressure pickup plugs (11) and (12),
and (13) and (14) (PT 1/8), or the hoses.
fl Hoses (15) and (16) use adapter C3.
• Plug (11): R.H. 4-spool control valve high-
pressure end
(No. 1 and No.2 rear pump)
• Plug (12): R.H. 4-spool control valve low-
pressure end
(No. 1 and No.2 rear pump)
• Plug (13): L.H. 5-spool control valve high-
pressure end
(No. 1 and No.2 front pump)
• Plug (14): L.H. 5-spool control valve low-
pressure end
(No. 1 and No.2 front pump)
2) Install oil pressure gauge C1 (high-pressure end:
5.88 MPa {60 kg/cm2}, low-pressure end: 2.45
MPa {25 kg/cm2}.
3) Measuring with control levers at neutral (differ-
ential pressure at maximum)
Run the engine at full throttle, set to the D.H
mode, and measure the differential pressure with
the control levers at neutral.
fl High pressure (Pt) – Low pressure (Pd) =
Differential pressure
fl The differential pressure is the maximum.
4) Measuring with control levers operated (differ-
ential pressure at minimum)
i) No. 1 pump, No. 2 pump
Using the work equipment, push up the track
frame on one side and measure the differ-
ential pressure with the track rotating under
no load (with the control levers operated
fully).

PC750, 800-6 20-55


TESTING AND ADJUSTING TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE

Adjusting
fl If the result of the measurement shows that the
differential pressure is not within the standard
value, adjust as follows.
• Plug (17): For L.H. 5-spool control valve
• Plug (18): For R.H. 4-spool control valve
1) Loosen locknut (19), then turn adjustment screw
(20) to adjust.
fl Turn the adjustment screw to adjust as fol-
lows.
To INCREASE pressure, turn CLOCKWISE.
To DECREASE pressure, turn COUNTER-
CLOCKWISE.
fl Amount of adjustment for one turn of holder:
Approx. 0.13 MPa (1.4 kg/cm2}
3 Locknut : 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
fl After completion of adjusting the adjustment
screw, repeat the procedure in “Measuring” Item
1 to check the set pressure again.

20-56 PC750, 800-6


TESTING AND ADJUSTING MEASURING SERVO PISTON STROKE

MEASURING SERVO PISTON


STROKE
fl If the NC valve output pressure is normal but
the performance of the pump seems to be de-
fective, check the servo valve as follows.

1. Tools to prepare
Make gauge q using the following parts.
1) Servo piston cap (type with built-in spring)
2) Brake wear measurement gauge for dump
truck (566-98-41120)
3) Cuts a PT 1/4 thread in the center of cap (1)
and install gauge q.

2. Measurement procedure
1) Remove the cap (with built-in spring) from
the part to be measured.
fl The cap is being pushed by the spring,
so use a bolt (01016-31070) and nut.
2) Fit removed shim (2) and install gauge q.
fl Be careful not to let the shim get caught
in the bolt thread.
3) Stop the engine, push the rod fully, and
measure dimension a of the rod.
4) Raise the track shoe from the ground on the
side where the gauge is fitted, then run the
engine at full throttle, rotate the track under
no load, and measure dimension a of the
rod.
fl Standard stroke b
No. 1 pump (HPV95+95):
Approx. 9.37 mm
No. 2 pump (HPV95+95):
Approx. 9.37 mm
fl When rotating the track shoe under no
load, push the rod in with your hand
and check at the same time that the rod
moves smoothly a distance that matches
the amount that the control lever is op-
erated.

PC750, 800-6 20-57


TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE

MEASURING PPC VALVE OUT-


PUT PRESSURE
fl Oil temperature when measuring: 45 – 55°C
1. Disconnect hose (1) of the circuit to be mea-
sured (see diagram below).

2. Install adapter C3 between the hose and elbow.

3. Install oil pressure gauge C1 (5.88 MPa {60 kg/


cm2}) to adapter C3.

4. Run the engine at full throttle, operate the con-


trol lever of the circuit to be measured, and
measure the oil pressure.

20-58 PC750, 800-6


TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE

TESTING SOLENOID VALVE


OUTPUT PRESSURE
Measuring output pressure of ON/OFF solenoid
valve
1. Disconnect outlet hoses (1) – (5) of the solenoid
valve to be measured, then use adapter C3 in
the oil pressure gauge kit to install oil pressure
gauge C1 (5.88 MPa {60 kg/cm2}).

2. Measure the solenoid valve output pressure un-


der the conditions in Table 1.

Table 1
Hose Solenoid Measurement conditions Operating conditions Condition of Oil pressure2 Remarks
solenoid (MPa {kg/cm })
Operate boom RAISE independently Pump discharge pressure Min. 2.74 MPa
2-stage with heavy-lift switch ON at high-pressure setting ON {28 kg/cm2}
1 main
relief Pump discharge pressure
Machine push-up switch OFF at low-pressure setting OFF 0

When machine push-up switch is at Safety valve at high-


high-pressure setting pressure setting OFF 0
Machine
2 push-up
When machine push-up switch is at Safety valve at low- Min. 2.74 MPa
low-pressure setting pressure setting ON {28 kg/cm2}
Swing and work equipment (travel) Flow from front Min. 2.74 MPa
control lever operated simultaneously pump divided ON {28 kg/cm2}
Straight
3 travel
All levers at neutral Flow not divided OFF 0

Travel motor swash Min. 2.74 MPa If pressure reaches


Travel speed switch at Hi plate angle at MIN ON {28 kg/cm2} high pressure of more
Travel than 22.56 MPa {230
4 speed kg/cm2}, speed is
Travel motor swash
Travel speed switch at Lo plate angle at MAX OFF 0 switched inside motor
to Lo
Swing or work equipment lever Brake canceled Min. 2.74 MPa
operated ON {28 kg/cm2}
Swing
5 holding Approx. 10 sec after all levers except Brake applied
brake travel lever are returned to neutral OFF 0

CO cancel Min. 2.74 MPa


In D.H mode ON {28 kg/cm2}
CO
6 cancel
In H or G mode CO valve actuated OFF 0

Operate boom RAISE with swing Flow amount Min. 2.35 MPa
priority switch OFF limited at swing OFF {24 kg/cm2}
Swing
7 priority All levers at neutral (swing priority
switch ON) Normal control ON 0

PC750, 800-6 20-59


TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT, SWING PPC VALVE

ADJUSTING WORK EQUIP-


MENT, SWING PPC VALVE
fl If there is excessive play in the work equipment
or swing lever, adjust as follows.
¤ Lower the work equipment to the ground and
stop the engine. Operate the control levers sev-
eral times to release the remaining pressure in
the hydraulic piping. Loosen the oil filler cap
slowly to release the pressure inside the hy-
draulic tank.
Then put the safety lock lever in the LOCK posi-
tion.
fl Lever play: 0.5 – 3 mm at point 200 mm from
center of lever installation pin

1. Loosen locknut (1), then turn disc (2) to adjust


the play of the lever.
fl When doing this, do not move the piston.

2. Secure disc (2) in position, then tighten locknut


(1) to the specified torque.
3 Locknut :
98.07 – 127.49 Nm {10 – 13 kgm}

20-60 PC750, 800-6


TESTING AND ADJUSTING TESTING TRAVEL DEVIATION

TESTING TRAVEL DEVIATION


fl When traveling on level ground.
1. Set the machine in the travel posture.
fl For the travel posture, extend the bucket and
arm cylinder rods fully, and hold the boom
angle at 45˚.

2. Travel for 10 m, then measure the deviation


when traveling for the next 20 m.
fl Set to DH mode and measure with the en-
gine at full throttle.
fl Measure on a flat, firm road surface or con-
crete road surface (surface with little travel
resistance).

PC750, 800-6 20-61


TESTING AND ADJUSTING TESTING TRAVEL DEVIATION

No. 1 pump
If the result of the measurement is not within
the standard value, adjust as follows.
fl Adjustment procedure

Deviation to right Deviation to left


Adjust by adding Adjust by adding
shim at front shim at rear
pump end a pump end b

• If the above adjustment procedure is fol-


lowed but the travel deviation is still not
within the standard value after adjustment,
see “TROUBLESHOOTING – Excessive travel
deviation”.
1) Loosen 4 bolts (1).
fl The shim is a split type, so it is not nec-
essary to remove the cap.
2) Add a thickness of shim (2) that matches the
amount of the deviation, then tighten bolt
(1).
fl Add a maximum shim thickness of 0.3
mm.
3 Mounting bolt :
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
fl Amount of deviation and shim thickness
to add
See graph
No. 1 pump (95+95)

20-62 PC750, 800-6


TESTING AND ADJUSTING TESTING TRAVEL DEVIATION

No. 2 pump

No. 2 pump (95+95)

PC750, 800-6 20-63


TESTING AND ADJUSTING TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT

TESTING LOCATIONS
CAUSING HYDRAULIC DRIFT
OF WORK EQUIPMENT
fl If there is any hydraulic drift in the work equip-
ment (cylinders), check as follows to determine
if the cause is in the cylinder packing or in the
control valve.
1. Checking for defective cylinder packing
1) Checking boom and bucket cylinders
i) Set in the same posture as when mea-
suring hydraulic drift, and stop the en-
gine.
ii) Operate the boom control lever to RAISE
or the bucket control lever to CURL.
• If the lowering speed increases, the
packing is defective.
• If there is no change, the boom lock
valve (boom) or the control valve
(bucket) is defective.
2) Checking arm cylinder
i) Stop the arm cylinder at a point approx.
100 mm before the end of the IN stroke,
then stop the engine.
ii) Operate the control lever to arm IN.
• If the lowering speed increases, the
packing is defective.
• If there is no change, the control BKP00159
valve is defective.
fl If the pressure in the accumulator
has dropped, run the engine for
approx. 10 seconds to charge the
accumulator again before operating.
[Reference] If the cause of the hydraulic drift is
in the packing, and the above opera-
tion is carried out, the downward
movement becomes faster for the
following reasons.
1) If the work equipment is set to the above
posture (holding pressure applied to the bot-
tom end), the oil at the bottom end leaks to
the head end. However, the volume at the
head end is smaller than the volume at the
bottom end by the volume of the rod, so the
internal pressure at the head end increases
because of the oil flowing in from the bot-
tom 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 dif-
fers according to the amount of leakage) by
repeating this procedure.
3) When the pressure is balanced, the down-
ward movement becomes slower. If the le-
ver is then operated according to the proce-
dure given above, the circuit at the head
end is opened to the drain circuit (the bot-
tom end is closed by the check valve), so
the oil at the head end flows to the drain
circuit and the downward movement be-
comes faster.
20-64 PC750, 800-6
TESTING AND ADJUSTING MEASURING OIL LEAKAGE

MEASURING OIL LEAKAGE


fl Oil temperature when measuring: 45 – 55˚C
1. Work equipment cylinder
fl If the hydraulic drift of the work equipment
is not within the standard value, measure
the leakage inside the cylinder as follows,
and judge if the cause of the hydraulic drift
is in the cylinder or in the control valve.
• If the leakage is within the standard
value, the problem is in the control valve.
• If the leakage is greater than the stan-
dard value, the problem is in the cylin-
der.
1) Fully extend the rod of the cylinder to be
measured, then stop the engine.
2) Disconnect piping (1) at the head end, then
block the piping at the chassis end with a
blind plug.
¤ Be careful not to disconnect the piping
at the bottom end.
3) Start the engine and apply the relief pres-
sure to the bottom end of the cylinder with
the engine at full throttle.
fl Boom cylinder: RAISE
Arm cylinder: IN
Bucket cylinder: CURL
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one
minute.

PC750, 800-6 20-65


TESTING AND ADJUSTING MEASURING OIL LEAKAGE

20-66 PC750, 800-6


TESTING AND ADJUSTING MEASURING OIL LEAKAGE

2. Swing motor
1) Disconnect drain hose (1) (front side motor),
(2) (rear side motor) from the swing motor,
then install a blind plug at the tank end.
2) Turn the swing lock switch ON.
3) Start the engine and operate the swing re-
lief with the engine at full throttle.
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one
minute.
fl After measuring, swing 180° and measure
again.

3. Travel motor
1) Disconnect drain hose (2) from the travel
motor, then fit a blind plug at the hose end.
2) Fit block (1) between the sprocket and frame
to lock the track.
3) Start the engine and operate the travel relief
with the engine at full throttle.
¤ When measuring the oil leakage from
the travel motor, mistaken operation of
the control lever may lead to a serious
accident, so always use signals and check
carefully when carrying out this opera-
tion.
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one
minute.
fl When measuring, move the motor slightly
(to change the position between the valve
plate and cylinder, and between the piston
and cylinder), and measure several times.

PC750, 800-6 20-67


TESTING AND ADJUSTING MEASURING OIL LEAKAGE

4. Center swivel joint


• If there is any abnormality when traveling
(travel deviation, lack of travel speed), and
there is no abnormality in the hydraulic
pumps or control valves, check as follows.
Table 1
Swivel joint Direction of rotation Swivel joint
inspection port of travel motor measurement port

A R.H. FORWARD B·T

B R.H. REVERSE A·P

C L.H. REVERSE P·D

D L.H. FORWARD C·T

P Speed selection B·C

1) Put block (1) between the sprocket and frame


to lock the rotation of the travel motor where
the port is to be inspected, and stop the
engine.
¤ Loosen the hydraulic tank oil filler cap
slowly to release the pressure inside the
tank.
2) Disconnect the hoses at the top of the swivel
for the measurement port at both sides of
the port to be inspected, and fit blind plugs
in the hoses.
fl For the combination of inspection port
and measurement port, see Table 1.
fl Use the following parts as blind plugs.
• Main hose: Flange (07379-01044)
Split flange (07371-31049)
Drain hose: Plug (07376-50315)
(07376-50628)
3) Start the engine, run the engine at full
throttle, and use a measuring cylinder to
catch the oil that leaks out from the mea-
surement port as follows.
i) Ports A, B, C, D
Relieve the travel motor slowly in the
direction of rotation for the port to be
inspected.
fl For the direction of rotation for the
port to be inspected, see Table 1.
ii) Port P
Set the travel speed switch to Hi.
4) Continue for one minute, then measure the
oil leakage for the next one minute.

20-68 PC750, 800-6


TESTING AND ADJUSTING MEASURING OIL LEAKAGE

PC750, 800-6 20-69


TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING

TESTING CLEARANCE OF
SWING CIRCLE BEARING
fl Measure the clearance of the swing circle bear-
ing as follows when it is mounted on the ma-
chine.
1. Fix a magnet-type dial gauge to the outer race
(or inner race) of the swing circle, then put the
tip of the probe in contact with the inner race
(or outer race).
Set the dial gauge at the front or rear.

2. Extend the work equipment to the maximum


reach, and set the tip of the bucket to the same
height as the bottom of the revolving frame.
When this is done, the upper structure will tilt
forward, so the front will go down and the rear
will rise.

3. Set the dial gauge to the zero point.

4. Set the arm more or less at right angles to the


ground surface, then lower the boom until the
front of the machine comes off the ground.
When this is done, the upper structure will tilt
back, so the front will rise and the rear will go
down.

5. Read the value on the dial gauge at this point.


The value on the dial gauge is the clearance of
the swing circle bearing.
¤ When carrying out the measurement, do not
put your hand or feet under the undercar-
riage.

6. Return to the condition in Step 2, and check that


the dial gauge has returned to the zero point. If
it has not returned to the zero point, repeat Steps
2 to 5.

20-70 PC750, 800-6


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 straight bar [1] on the track shoe between


the 2nd and the 3rd carrier roller.
fl 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

ADJUSTING
fl 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 (1).
¤ Do not loosen valve (1) 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 (2).
fl If the normal track shoe tension is not re-
stored even after greasing, move the ma-
chine slowly back and forth.

PC750, 800-6 20-71


2
TESTING AND ADJUSTING BLEEDING AIR

BLEEDING AIR

Air bleeding item Air bleeding procedure


1 2 3 4 5
Bleed air Bleed air from Bleed air from Start
from pump Start engine operations
Nature of work cylinder swing motor

• Change hydraulic oil


• Clean strainer (note)

• Replace return filter element

• Replace, repair pump


• Remove suction piping

• Replace, repair control valve

• Replace cylinder
• Remove cylinder piping
• Replace swing motor
• Replace safety valve of motor
• Remove swing motor piping
• Replace travel motor, swivel
• Remove travel motor, swivel piping

Note: Bleed the air from the swing motor only when the oil inside the motor case has been drained.

1. Bleeding air from pump


1) Loosen air bleed plug (1), and check that oil
oozes out from the plug.
2) When oil oozes out, tighten plug (1).
3 Air bleed plug:
8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}
fl If no oil oozes out from the air bleed plug:
3) Leave plug (1) loosened and remove drain
hose (2) and elbow (3).
4) Pour in oil through the elbow mount hole
until oil oozes out from plug (1).
5) Fit elbow (3) and install drain hose (2).
6) Tighten air bleed plug (1).
3 Air bleed plug:
8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}
fl Precautions when starting the engine
After completing the above procedure and
starting the engine, run the engine at low
idling for approx. 10 minutes.
fl If the coolant temperature is low and auto-
matic warming-up is carried out, cancel it by
using the fuel control dial.

20-72 PC750, 800-6


TESTING AND ADJUSTING BLEEDING AIR

2. Bleeding air from hydraulic cylinders


1) Start the engine and run at idling for approx.
5 minutes.
2) Run the engine at low idling, then raise and
lower the boom 4 – 5 times in succession.
fl Operate the piston rod to a point approx.
100 mm before the end of its stroke. Do
not relieve the circuit under any circum-
stances.
3) Run the engine at full throttle and repeat
Step 2). After that, run the engine at low
idling, and operate the piston rod to the end
of its stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air from
the arm and bucket cylinders.
fl When the cylinder has been replaced,
bleed the air before connecting the pis-
ton rod.
Be particularly careful not to operate the
cylinder to the end of its stroke when
the piston rod has been connected to
the LOWER end of the boom cylinder.

PC750, 800-6 20-73


BLEEDING AIR
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT

3. Bleeding air from swing motor


1) Inside motor case
Run the engine at low idling for approx. 5
minutes.
fl This operation will bleed the air inside
the motor case automatically.
2) Inside brake case
fl Normally, the air inside the brake case is
bled automatically, but if it feels that the
brake is dragging when operating the
swing, bleed the air as follows.
Loosen the mouthpiece of brake hose (1),
start the engine, and operate the swing pro-
lix switch ON-OFF repeatedly. When oil oozes
out, tighten the mouthpiece.
3) Inside safety valve drain case
fl Normally, the air inside the safety valve
drain case is automatically bled, but if
abnormal noise is generated from around
the swing motor safety valve during
swing operations, bleed the air as fol-
lows.
Remove plugs (3) and (4) on top of the el-
bow at the swing suction port, operate the
swing slowly at low idling, and when no
more cloudy white oil comes out, tighten
plugs (3) and (4).
3 Plug: 11.27 ± 1.4 Nm {1.15 ± 0.15 kgm}
fl When bleeding the air, the air can be
bled more easily if plugs (3) and (4) are
removed and nipple C2 and coupling C6
are installed.

RELEASING REMAINING
PRESSURE IN
HYDRAULIC CIRCUIT
fl If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure from the circuit as fol-
lows.
The travel circuit is an open circuit, so there is
no remaining pressure. It is enough to remove
the oil filler cap.

1. Loosen the oil filler cap slowly to release the


pressure inside the tank.
2. Operate the control levers.
fl When the levers are operated 2 – 3 times,
the pressure stored in the accumulator is
removed.
3. Start the engine, run at low idling for approx. 5
minutes, then stop the engine and operate the
control levers.
fl Repeat the above operation 2 – 3 times to
release all the remaining pressure.

20-74 PC750, 800-6


TESTING AND ADJUSTING PROCEDURE FOR CHECKING DIODE

PROCEDURE FOR CHECKING


DIODE
• Use the following procedure to check the diode
as individual part and the wiring harness con-
taining the diode.
• Use a digital tester with a range for measuring
diodes.

1. Put the red (+) end of the test pin in contact with
the anode (P) of the diode, and the black (–) end
in contact with the cathode (N).
fl There is a mark showing the direction of
continuity on the surface of the diode.
fl If a normal tester is switched to the diode
range, the voltage of the internal battery is
displayed. The value indicates the following.
• No change: No continuity
• Changes: There is continuity (normal)
(Note)
• Value is 0 or near 0: Short circuit inside
diode
Note: In the case of silicon diodes, a value be-
tween 400 and 600 is displayed. Depend-
ing on the type of tester, a value between
0.4 and 0.6 is displayed.

PC750, 800-6 20-75


TROUBLESHOOTING

Points to remember when troubleshooting ........................................................................................ 20-102


Sequence of events in troubleshooting .............................................................................................. 20-103
Points to remember when carrying out maintenance ....................................................................... 20-104
Checks before troubleshooting ............................................................................................................ 20-112
Connector types and mounting locations ........................................................................................... 20-113
Connection table for connector pin numbers .................................................................................... 20-120
Explanation of control mechanism of electrical system ................................................................... 20-143
Display method and special functions of monitor panel .................................................................. 20-144
Method of using judgement table ....................................................................................................... 20-159
Method of using troubleshooting charts ............................................................................................ 20-161
Details of troubleshooting and troubleshooting procedure ............................................................. 20-162
Troubleshooting of communication abnormality system (N mode) ............................................... 20-201
Troubleshooting of engine controller system (E mode) ................................................................... 20-251
Troubleshooting of pump controller system (C mode) ............................................................................. 20-401
Troubleshooting of engine throttle, pump controller [input signal system] (F mode) ................. 20-501
Troubleshooting of hydraulic, mechanical system (H mode) ........................................................... 20-551
Troubleshooting of monitor panel system (M mode) ....................................................................... 20-601

PC750, 800-6 20-101


TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING


¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
¤ 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.
¤ 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.
¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
¤ 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 4) Check the stroke of the control valve spool.
to disassemble the components. 5) Other maintenance items can be checked
If components are disassembled immediately any externally, so check any item that is consid-
failure occurs: ered to be necessary.
• Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- • Confirm the extent of the failure yourself,
sembled. and judge whether to handle it as a real fail-
• It will become impossible to find the cause ure or as a problem with the method of op-
of the failure. eration, etc.
It will also cause a waste of manhours, parts, or fl When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting in • Use the results of the investigation and in-
accordance with the fixed procedure. spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart from ing flowchart to locate the position of the
the problem that has been reported? failure exactly.
2) Was there anything strange about the ma- fl The basic procedure for troubleshooting
chine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or in-
4) Under what conditions did the failure occur? formation.
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? • Even if the failure is repaired, if the root cause
When were these repairs carried out? of the failure is not repaired, the same failure
6) Has the same kind of failure occurred be- will occur again.
fore? To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.

20-102 PC750, 800-6


TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

Office, shop Jobsite


TEW00180 TEW00181

Step 1
Examination, confirmation of symptoms

1) When a request for repairs is received, first


ask the following points. Ring Ring
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
• Condition of failure
• Work being carried out at the time of the TEW00182
failure
• Operating environment
• Past history, details of maintenance, etc. Breakdown

Step 2
Determining probable location of cause TEW00183

1) Look at the troubleshooting section of the


shop manual to find locations of possible Step
causes.
Repair at jobsite

Hurray !
TEW00184 It's repalred

Step 3
Preparation of troubleshooting tools
TEW00185
1) Look at the table of troubleshooting tools in
the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
TEW00186 repair simple failures.
• Check before starting items
• Other check items
2) See the Troubleshooting Section of the shop
Step 8
manual, select a troubleshooting flowchart
Repair at workshop that matches the symptoms, and carry out
troubleshooting.
TEW00187

Step 6
Machine
volume Re-enacting failure

• Drive and operate the machine to confirm


Shop manual the condition and judge if there is really a
failure.
TEW00188

Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.

• Was there anything strange about the ma-


chine before the failure occurred?
• Did the failure occur suddenly?
• Had any repairs been carried out before the
TEW00189 failure?
TEW00190

PC750, 800-6 20-103


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 re-
pairs 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, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted 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 fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191

Main failures occurring in wiring harness


1 Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
Improper insertion
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.

TEW00192

2 Defective crimping or soldering of connec-


tors
The pins of the male and female connectors
are in contact at the crimped terminal or Crimped portion
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.

TEW00193

20-104 PC750, 800-6


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 solder-
ing may be damaged, or the wiring may be
broken.

TEW00194

4 High-pressure water entering connector


The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, 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-
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity 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 sur-
face 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 connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
fl When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
fl 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 clean-
ing with compressed air.

PC750, 800-6 20-105


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 Press lightly
when removing
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully, Lock stopper
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 con-
TEW00197
nectors apart.
fl 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.
fl If the connector is twisted up and down
or to the left or right, the housing may
break.

TBW00484

Catches

TBW00485

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.
fl If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.

TEW00198

20-106 PC750, 800-6


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 por-
tion).
2) Check that there is no deformation, de-
Cliks into position
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
fl If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
TEW00199
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
fl If there is any damage or breakage, re-
place 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.
TEW00200
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 po-
sition.
fl If the connector cannot be corrected eas-
ily, 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. TBW00487

PC750, 800-6 20-107


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 wa-
ter 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.
fl If the connector is blown dry with com- TEW00196
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed 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.
fl 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 connec-
tor.

TEW00202

3 Carry out a continuity test on the connector.


After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
fl After completely drying the connector,
blow it with contact restorer and reas-
semble. T-adapter

TEW00203

20-108 PC750, 800-6


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.

TEW00204

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 con-
trol box in a place where it is exposed to
rain.

TEW00205

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 weld-
ing ground close to the welding point.

TEW00206

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.
fl Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
fl 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.
fl If there is any change, there is probably defective contact in that circuit.

PC750, 800-6 20-109


TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. POINTS TO REMEMBER WHEN HANDLING


HYDRAULIC EQUIPMENT

With the increase in pressure and precision of hy-


draulic equipment, the most common cause of fail-
ure 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. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equipment.
TEW00207

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 en-
tering. 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 leak-
ing 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.
TEW00208

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 clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

TEW00209

20-110 PC750, 800-6


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 pos-
sible 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 equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil Flushing oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.

TEW00210

7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, 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 re-
move, so it is an extremely effective device.

TEW00211

PC750, 800-6 20-111


TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Item Judgement Action


value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil, coolant

3. Check hydraulic oil level — Add oil


4. Check hydraulic strainer — Clean, drain
5. Check swing machinery oil level — Add oil
6. Check engine oil level (oil pan oil level), type of oil — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
equipment

1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace


Electrical

2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace


3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
mechanical
equipment
Hydraulic,

1. Check for abnormal noise, smell — Repair


2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air

1. Check battery voltage (engine stopped) 20 – 30V Replace


2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment

3. Check for discolored, exposed wiring — Replace


4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention — Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After running Replace
for several
minutes:
27.5 - 29.5 V

8. Check operating sound of battery (when switch is turned ON/OFF) — Replace

20-112 PC750, 800-6


TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

CONNECTOR TYPES AND MOUNTING LOCATIONS


fl The Address column in the table shown the address in the connector arrangement drawing (3-
dimension drawing).
Con- No. Add- Con- No. Add-
nector Type of Mounting location nector Type of Mounting location
ress ress
No. pins No. pins
B01 HD30 21 Circuit breaker box B-9 D05 KES1 2 Diode (for swing holding brake solenoid) Q-8

B02 DT 1 Circuit breaker box C-9 D06 YSKD 4 Diode (for solenoid) O-9

B03 DT 1 Circuit breaker box B-9 D08 KES1 2 Diode (for window washer) Q-9

B11 Terminal 1 Circuit breaker (80A) C-9 D11 KES1 2 Diode (for buzzer) M-4

B12 Terminal 1 Circuit breaker (20A) C-9 D14 KES1 2 Diode (for battery relay) R-8

B13 Terminal 1 Circuit breaker (20A) C-9 D17 KES1 2 Diode (for ribbon heater) Q-9

B14 Terminal 1 Circuit breaker (20A) C-9 D20 KES1 4 Diode (for boom shockless solenoid valve) R-8

B15 Terminal 1 Circuit breaker (20A) C-9 D22 KES1 2 Diode (for R.H. travel pressure switch) P-8
B16 Terminal 1 Circuit breaker (20A) C-9 D23 KES1 4 Diode (for L.H. travel pressure switch) O-8

B17 Terminal 1 Circuit breaker (20A) C-9 D26 KES1 2 Diode (for swing holding brake switch) O-8

B18 Terminal 1 Circuit breaker (20A) C-9 D28 KES1 2 Diode (for boom RAISE pressure switch) R-8

B19 Terminal 1 Circuit breaker (20A) C-9 D29 KES1 2 Diode (for flash light) Q-1

B21 Terminal 1 Circuit breaker (80A) C-9 D30 KES1 2 Diode (for lower wiper) Q-8

B22 Terminal 1 Circuit breaker (20A) C-9 D31 KES1 2 Diode (for step light) Q-2

B23 Terminal 1 Circuit breaker (20A) C-9 D32 KES1 2 Diode (for step light) R-2

B24 Terminal 1 Circuit breaker (20A) C-9 D34 KES1 2 Diode (for step light) R-1

B25 Terminal 1 Circuit breaker (20A) C-9 D35 KES1 2 Diode (for flash light) R-1

B26 Terminal 1 Circuit breaker (20A) C-9 E06 M 3 Fuel control dial N-6
B27 Terminal 1 Circuit breaker (20A) C-9 E09 S 8 Model selection connector (engine controller) R-3

B28 Terminal 1 Circuit breaker (20A) C-9 E11 070 12 Engine controller Q-7

B29 Terminal 1 Circuit breaker (20A) C-9 E12 070 18 Engine controller R-7

B1A Terminal 1 Circuit breaker (20A) C-9 E13 040 8 Engine controller R-6

B2A Terminal 1 Circuit breaker (20A) C-9 E14 070 20 Engine controller R-6

C01 MIC 13 Pump controller O-6 E15 040 16 Engine controller R-5

C02 MIC 21 Pump controller O-7 E16 070 10 Engine controller R-6

C03 040 20 Pump controller P-7 E17 070 14 Engine controller Q-7

C05 S 10 Emergency pump drive switch N-2 E21 HD30 31 Intermediate connector (engine) K-9

C06 M 2 Emergency pump drive resister P-2 E22 HD30 31 Intermediate connector (engine) K-8

C09 S 8 Model selection connector (pump controller) Q-7 CN1 DT 2 No.1 fuel injector U-9

C13 DT 2 TVC valve L-6 CN2 DT 2 No.2 fuel injector U-9

C16 MIC 17 Pump controller P-7 CN3 DT 2 No.3 fuel injector V-9

C17 040 16 Pump controller O-6 CN4 DT 2 No.4 fuel injector V-9

D01 KES1 2 Diode (for car heater) R-9 CN5 DT 2 No.5 fuel injector W-9

D03 YSKD 4 Diode (for solenoid) P-9 CN6 DT 2 No.6 fuel injector W-9

PC750, 800-6 20-113


TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

Con- No. Add- Con- No. Add-


nector Type of Mounting location nector Type of Mounting location
ress ress
No. pins No. pins
PCV1 DENSO 2 Fuel supply pump PSV1 S-7 M38 Terminal 1 Horn (low tone) B-1

PCV2 DENSO 2 Fuel supply pump PSV2 S-7 M38 M 2 Machine push-up switch N-7
1-pin
E60 M 2 Intermediate connector (engine controller) Q-7 M39 connector 1 Service connector (for add-on light) P-7

ENE DT 2 Engine speed sensor X-6 M42 M 1 R.H. working lamp A-3

F01 X 2 Travel alarm J-9 M44 M 4 Intermediate connector (automatic greasing) N-6

G DENSO 2 Engine generator rotation sensor S-6 M45 M 3 Network bus connector M-2

G01 X 2 Grease pump A-6 M62 S 8 Intermediate connector (loader spec.) R-3
1-pin
G02 X 2 Grease pump switch A-2 M69 connector 1 Service power source connector Q-7
1-pin
H07 X 4 Intermediate connector (lower wiper) D-1 M70 connector 1 Service power source connector M-4
1-pin
H12 S(white) 16 Intermediate connector (base) F-1 M71 connector 1 Intermediate connector (room lamp) Q-2
H13 S(blue) 16 Intermediate connector (base) F-1 M72 X 3 Intermediate connector (cab top light) C-1

H14 M 8 Intermediate connector (base) D-9 M73 KES0 2 L.H. speaker P-7

H15 L 2 Intermediate connector (base) F-9 M73 M 3 Intermediate connector A-3

HT Terminal — Intake air heater relay X-7 M74 M 1 Cab top light A-1

L03 M 2 Step light switch G-1 M75 M 1 Step light E-1

M06 M 3 Heater switch N-7 M76 M 1 Cab top light C-1

M07 M 2 Lamp switch M-7 M80 X 1 Intermediate connector (flash light) E-1

M08 M 1 Boom working lamp A-9 M81 M 2 Intermediate connector (step light) R-3

M09 M 1 Working lamp A-9 M82 M 1 Flash light E-1

M10 X 1 Intermediate connector E-9 M91 KES1 4 Lower wiper switch O-8
M12 KES1 3 Heater unit Q-2 M93 1-pin 1 Service power source connector M-3
connector

M13 KES0 2 R.H. speaker R-6 M94 M 4 Intermediate connector (network) N-6

M16 Terminal 1 Horn (high tone) A-1 M95 M 4 Intermediate connector (horn) C-1

M17 Terminal 1 Horn (low tone) B-1 NE DENSO 2 Engine NE rotation sensor W-5

M18 M 4 Wiper and washer switch M-7 OL DT 2 Engine oil level sensor U-5
1-pin
M20 connector 2 Cigar lighter N-6 P01 040 20 Monitor panel M-4

M21 PA 9 Radio N-6 P02 040 16 Monitor panel M-5

M23 M 2 Intermediate connector (horn switch) N-6 P03 M 2 Buzzer cancel switch N-7

M26 M 6 Air conditioner unit Q-3 P04 M 2 Alarm buzzer M-5

M28 KES0 2 Window washer motor I-1 P06 DT 2 Fuel level sensor A-8

M33 250 3 Boom shockless control switch N-8 P08 X 2 Radiator water level sensor (No.1) L-7

M34 X 1 Air compressor clutch I-9 P09 DT 2 Hydraulic oil level sensor L-5

M36 M 1 Kerosene mode selector switch F-1 P10 DT 2 Hydraulic oil temperature sensor L-5

M37 Terminal 1 Horn (high tone) A-1 P11 DT 2 Air cleaner clogging sensor I-9

20-114 PC750, 800-6


TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

Con- No. Add- Con- No. Add-


nector Type of Mounting location nector Type of Mounting location
ress ress
No. pins No. pins
P20 X 2 Radiator water level sensor (No.2) L-8 T07 Terminal 1 Pump controller GND Q-2

PFUEL DENSO 3 Fuel common rail pressure sensor T-5 T08 Terminal 1 Engine controller GND R-4

PIM DENSO 3 Boost pressure sensor X-7 T09 Terminal 1 Revolving frame GND A-4

PSH Terminal 1 Engine oil high pressure sensor T-5 T10 Terminal 1 Revolving frame GND D-9

PSL Terminal 1 Engine oil low pressure sensor V-5 THL DT 2 Spill fuel temperature sensor U-5

R04 Sinagawa 5 Front light relay M-5 TWH DT 2 Engine water high temperature sensor U-1

R05 Sinagawa 5 Boom light relay M-5 TWL DT 2 Engine water low temperature sensor T-1

R11 Sinagawa 5 Lower wiper relay M-5 V01 DT 2 Swing priority selector solenoid L-4

R15 Sinagawa 5 Boom shockless relay N-2 V02 DT 2 Heavy lift (2-stage relief) solenoid L-6

R16 Sinagawa 5 Flash light relay R-5 V03 DT 2 Straight-travel solenoid L-6
R17 Sinagawa 5 Step light relay R-4 V04 DT 2 Swing holding brake solenoid F-9

R18 Sinagawa 5 Flash light relay R-5 V05 DT 2 Machine push-up solenoid L-7

R24 Sinagawa 5 Engine controller power source relay R-3 V06 DT 2 Travel speed solenoid L-8

R25 Sinagawa 5 Step light relay R-4 V07 DT 2 CO cancel solenoid L-5

S01 X 2 R.H. travel (forward) PPC oil pressure switch G-1 V09 DT 2 Boom shockles (RAISE) solenoid J-1

S02 X 2 Boom RAISE PPC oil pressure switch K-2 V10 DT 2 Boom shockles (LOWER) solenoid J-1
1-pin
S03 X 2 Arm OUT PPC oil pressure switch L-3 W03 connector 1 Window rear limit switch E-9

S04 X 2 Boom LOWER PPC oil pressure switch K-2 W04 M 6 Wiper motor M-3

S05 X 2 Arm IN PPC oil pressure switch L-3 W08 070 18 Relay box (for wiper) P-2

S06 X 2 Bucket CURL PPC oil pressure switch L-2 W10 M 4 Intermediate connector (rear limit switch) Q-2
S07 X 2 Bucket DUMP PPC oil pressure switch L-2 W15 KES0 4 Lower wiper D-1

S08 X 2 R.H. swing PPC oil pressure switch L-4 X01 MIC 21 Intermediate connector (panel) O-7

S09 X 2 Service PPC oil pressure switch J-1 X05 M 4 Swing lock switch M-7

S10 X 2 L.H. swing PPC oil pressure switch L-4 X07 MIC 17 Intermediate connector (panel) O-7

S11 X 2 R.H. travel (reverse) PPC oil pressure switch H-1 BR Terminal 1 Battery relay A-6

S12 X 2 L.H. travel (forward) PPC oil pressure switch H-1 E Terminal 1 Battery relay A-7

S13 X 2 L.H. travel (reverse) PPC oil pressure switch I-1 B Terminal 1 Battery relay A-7

ST DT 2 Starter T-1 M Terminal 1 Battery relay A-8

SW01 Terminal 6 Swing holding brake switch M-3

T02 Terminal 1 Revolving frame GND A-5

T03 Terminal 1 Revolving frame GND A-5

T04 Terminal 1 Revolving frame GND A-4

T05 Terminal 1 Revolving frame GND A-4

T06 Terminal 1 Revolving frame GND A-4

PC750, 800-6 20-115


TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

20-116 PC750, 800-6


TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

PC750, 800-6 20-117


TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

20-118 PC750, 800-6


TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

PC750, 800-6 20-119


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS


fl 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.

No. X-type connector


of
Male (female housing) Female (male housing) T-adapter
pins 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 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20

Terminal part No.: 79A-222-3380 Terminal part No.: 79A-222-3410


— • Electric wire size: 2.0 • Electric wire size: 2.0 —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20

20-120 PC750, 800-6


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. SWP-type connector


of
Male (female housing) Female (male housing) T-adapter
pins Part No.

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 Part No.: 08055-11491

PC750, 800-6 20-121


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. SWP-type connector


of
Male (female housing) Female (male housing) T-adapter
pins Part No.

16 799-601-7320

Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:


• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20

Terminal part No.: Terminal part No.:


• Electric wire size: 1.25 • Electric wire size : 1.25
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20

20-122 PC750, 800-6


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. M-type connector


of
T-adapter
pins Male (female housing) Female (male housing)
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

8 799-601-7390

Part No.: 08056-00871 Part No.: 08056-00881

PC750, 800-6 20-123


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. S-type connector


of
Male (female housing) Female (male housing) T-adapter
pins Part No.

8 799-601-7140

Part No.: 08056-10871 Part No.: 08056-10881

10 799-601-7150
(White)

Part No.: 08056-11071 Part No.: 08056-11081

12 799-601-7350
(White)

Part No.: 08056-11271 Part No.: 08056-11281

16
799-601-7330
(White)

Part No.: 08056-11671 Part No.: 08056-11681

20-124 PC750, 800-6


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. S-type connector


of
Male (female housing) Female (male housing) T-adapter
pins Part No.

10 —
(Blue)

— —

12 799-601-7160
(Blue)

Part No.: 08056-11272 Part No.: 08056-11282

16 799-601-7170
(Blue)

Part No.: 08056-11672 Part No.: 08056-11682

PC750, 800-6 20-125


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. MIC-type connector


of
T-adapter
pins Male (female housing) Female (male housing)
Part No.

Body part No.: 79A-222-2640 Body part No.: 79A-222-2630


7 —
(Q’ty: 5) (Q’ty: 5)

Body part No.: 79A-222-2680 Body part No.: 79A-222-2670


11 —
(Q’ty: 5) (Q’ty: 5)

5 799-601-2710

Body part No.: 79A-222-2620 Body part No.: 79A-222-2610


(Q’ty: 5) (Q’ty: 5)

9 799-601-2950

Body part No.: 79A-222-2660 Body part No.: 79A-222-2650


(Q’ty: 5) (Q’ty: 5)

13 799-601-2720

Body part No.: 79A-222-2710 Body part No.: 79A-222-2690


(Q’ty: 2) (Q’ty: 2)

20-126 PC750, 800-6


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. MIC-type connector


of
Male (female housing) Female (male housing) T-adapter
pins Part No.

17 799-601-2730

Body part No.: 79A-222-2730 Body part No.: 9A-222-2720


(Q’ty: 2) (Q’ty: 2)

21 799-601-2740

Body part No.: 79A-222-2750 Body part No.: 79A-222-2740


(Q’ty: 2) (Q’ty: 2)
Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760

(Q’ty: 50) (Q’ty: 50)

PC750, 800-6 20-127


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. AMP040-type connector


of
Male (female housing) Female (male housing) T-adapter
pins Part No.

8 799-601-7180

— 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)
fl Terminal part No.: 79A-222-3470 (No relation with number of pins)

20-128 PC750, 800-6


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. AMP070-type connector


of
Male (female housing) Female (male housing) T-adapter
pins Part No.

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

— Part No.: 08195-20210

PC750, 800-6 20-129


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. L-type connector


of
Male (female housing) Female (male housing) T-adapter
pins
Part No.

2 —

— —

No. Connector for PA


of
Male (female housing) Female (male housing) T-adapter
pins Part No.

9 —

— —

No. Bendix MS connector


of
T-adapter
pins Male (female housing) Female (male housing)
Part No.

10 799-601-3460

— —

20-130 PC750, 800-6


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. KES 1 (Automobile) connector


of
Male (female housing) Female (male housing) T-adapter
pins Part No.

2 —

Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)

3 —

Part No.: 08027-10310 Part No.: 08027-10360

4 —

Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)

6 —

Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)

PC750, 800-6 20-131


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. KES 1 (Automobile) connector


of
Male (female housing) Female (male housing) T-adapter
pins
Part No.

8 —

Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)

20-132 PC750, 800-6


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. Connector for relay (Socket type)


of
T-adapter
pins Male (female housing) Female (male housing)
Part No.

5 799-601-7360

— —

6 799-601-7370

— —

PC750, 800-6 20-133


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. F-type connector


of
Male (female housing) Female (male housing) T-adapter
pins Part No.

4 —

— —

20-134 PC750, 800-6


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector
(shell
size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female termial)

799-601-9210

Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,


18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)

799-601-9210

Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,


08191-12205, 08191-12206 08191-13105, 08191-13106
Pin (male terminal) Pin (female termial)

799-601-9220

Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,


18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
(2) Pin (female terminal) Pin (male termial)

799-601-9230

Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,


08191-22205, 08191-22206 08191-23105, 08191-23106

PC750, 800-6 20-135


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector


(shell
size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female termial)

799-601-9230

18-20 Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102


(3) 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 Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102


(4) Pin (female terminal) Pin (male termial)

799-601-9240

Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102

20-136 PC750, 800-6


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector
(shell
size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female termial)

799-601-9250

24-9 Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102


(5) 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, Part No.: 08191-64101, 08191-64102,


24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
(6) Pin (female terminal) Pin (male termial)

799-601-9260

Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,


08191-62205, 08191-62206 08191-63105, 08191-63106

PC750, 800-6 20-137


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector


(shell
size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female termial)

799-601-9270

Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,


24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
(7) Pin (female terminal) Pin (male termial)

799-601-9270

Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,


08191-72205, 08191-72206 08191-73105, 08191-73106
Pin (male terminal) Pin (female termial)

799-601-9280

Part No.: 08191-81201, 08191-81202, 08191-81203, Part No.: 08191-84101, 08191-84102, 08191-84103,
24-22 08191-81204, 08191-81205, 08191-80206 08191-84104, 08191-84105, 08191-84106
(8) Pin (female terminal) Pin (male termial)

799-601-9280

Part No.: 08191-82201, 08191-82202, 08191-82203, Part No.: 08191-83101, 08191-83102, 08191-83103,
08191-82204, 08191-82205, 08191-82206 08191-83104, 08191-83105, 08191-83106

20-138 PC750, 800-6


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector
(shell
size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female termial)

799-601-9290

Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,


24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
(9) Pin (female terminal) Pin (male termial)

799-601-9290

Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,


08191-92205, 08191-92206 08191-93105, 08191-93106

PC750, 800-6 20-139


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

No. DT Series connector


of T-adapter
pins Body (plug) Body (receptacle)
Part No.

2 799-601-9020

Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)

3 799-601-9030

Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)

4 799-601-9040

Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)

6 799-601-9050

Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)

20-140 PC750, 800-6


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

No. DT Series connector


of T-adapter
pins Body (plug) Body (receptacle)
Part No.

8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090

Part No.: 08192-1820 (normal type) Part No.: 08192-1810 (normal type)
08192-2820 (fine wire type) 08192-2810 (fine wire type)

12GR:799-601-9110
12B: 799-601-9120
10 12G: 799-601-9130
12BR:799-601-9140

Part No.: 08192-1920 (normal type) Part No.: 08192-1910 (normal type)
08192-2920 (fine wire type) 08192-2910 (fine wire type)

PC750, 800-6 20-141


TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

No. DTM Series connector


of
Body (plug) Body (receptacle) T-adapter
pins Part No.

2 799-601-9010

Part No.: 08192-02200 Part No.: 08192-02100

[The pin No. is also marked on the connector (electric wire insertion end)]

No. DTHD Series connector


of
Body (plug) Body (receptacle) T-adapter
pins Part No.

2 —

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)

20-142 PC750, 800-6


TROUBLESHOOTING EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM

EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL


SYSTEM
The control mechanism for the electrical system consists of the monitor panel, the engine controller
and the controller. The monitor panel, the engine controller and the pump controller input the signals
that are necessary, and together with the signals selected by the monitor panel, the engine controller
and the pump controller outputs or inputs or inputs the necessary signals and control the pump
absorption torque and engine output.

PC750, 800-6 20-143


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR


PANEL

In addition to the normal observation and display


functions for the machine and the switch functions
of the control system, the monitor panel is also
equipped with the following special functions.
1. Troubleshooting function for lamps, gauges, and
buzzer (monitor display troubleshooting)
2. Display function for user code
3. Display function for service code
4. Display function for monitoring code
5. Setting function for reduced cylinder mode op-
eration
6. Setting function for working mode default, swing
priority mode
7. Setting function for oil maintenance display
8. Adjustment function for time display

1. Troubleshooting function of lamps, gauges,


buzzer
When the starting switch is turned ON, all the
lamps and gauges light up for approx. 3 sec-
onds, and the buzzer sounds for approx. 1 sec-
ond. During this time, the monitor itself carries
out self diagnosis, and after it has finished, it
gives the normal display (if any lamp dose not
light up during the visual check, the lamp bulb
is blown).

20-144 PC750, 800-6


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

2. User code display function


All the abnormality data for the engine control-
ler and the pump controller are transmitted to
the monitor panel.
Of the abnormality data, items with a high emer-
gency level are displayed as a user code auto-
matically on the time display (1) of the monitor
panel to advise the operator of the action to
take.
Example of display:
The right diagram shows the case when the
user code is displayed E02.

User code Abnormal system

E02 TVC system

E03 Swing holding brake system

E0E Network system

E10 Engine emergency stop system

E11 Engine control system

E14 Fuel control dial system

E15 Engine controller slightly failure

3. Service code display function


All the abnormality data for the engine control-
ler and the pump controller are transmitted to
the monitor panel.
These abnormality data, regardless of whether
they are necessary to display as a user code or
not, are all stored inside the monitor panel as
service codes.
When the following operations are carried out,
the service codes are displayed on the monitor
panel time display (1) and the elapsed time data
(time on the service meter) are displayed on the
service meter display panel (2).
1) To switch to the service code display mode,
keep the Time switch (3) + L.H. travel speed
switch (4) pressed for at least 2.5 seconds.
Example)
A: When the display shows that [E213] oc-
curred 6 hours before.

PC750, 800-6 20-145


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

B: When [E213] occurred 6 hours before and


the display shows that the abnormality
is still continuing, the letter “E” appears
at the head of the code.
C: When the service code is not recorded,
only center segments displayed.
2) To go on to the next service code display,
press the Time switch (3) + Working mode
right switch (5).
3) To go back to the previous code service code
display, press the Time switch (3) + Working
mode left switch (6).
4) To finish using the service code display
mode, keep the Time switch (3) + L.H. travel
speed switch (4) pressed for at least 2.5 sec-
onds.
5) To delete the service codes from memory,
keep the Time switch (3) pressed and turn
the starting switch OFF. Then turn the start-
ing switch ON again and keep the Time
switch (3) pressed for at least 2.5 seconds.

Table of service codes


Service code Abnormal system User code
E101 Abnormality in error history data —
E102 Abnormality in clock data —
E103 Short circuit in buzzer output system —
E104 Abnormality in air cleaner clogging sensor detected —
E108 Engine water temperature over 105°C detected —
E112 Short circuit in wiper forward drive system —
E113 Short circuit in wiper reverse drive system
E114 Short circuit in window washer drive system —
E117 S-NET communication error in between engine controllers E0E
E118 S-NET communication error in between pump controllers E0E
E201 Short circuit in CO cancel solenoid system —
E202 Short circuit in straight-travel solenoid system —
E203 Short circuit in swing holding brake solenoid system E03
E204 Short circuit in 2-stage relief solenoid system —
E205 Short circuit in swing priority selector solenoid system —
E206 Short circuit in travel speed solenoid system —
E207 Short circuit in flash light relay system —

20-146 PC750, 800-6


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

Service code Abnormal system User code


E211 Disconnection in CO cancel solenoid system —
E212 Disconnection in straight-travel solenoid system —
E213 Disconnection in swing holding brake solenoid relay system E03
E214 Disconnection in 2-stage relief solenoid system —
E215 Disconnection in swing priority selector solenoid system —
E216 Disconnection in travel speed solenoid system —
E217 Error in model selection input —
E218 S-NET response overtime error —
E227 Abnormality in engine sped sensor system —
E228 Abnormality in auto-deceleration output system —
E231 Abnormality in step light power source keeping output system —
E232 Short circuit in TVC solenoid system E02
E233 Disconnection in TVC solenoid system —
E302 Short circuit in step light relay drive system —
E303 Disconnection in step light relay drive system —
E313 Error in automatic greasing controller system —
E91b Abnormality in engine NE rotation sensor system E11, E10 (Note1)
E91C Abnormality in engine G rotation sensor system E11, E10 (Note1)
E920 Abnormality in engine controller model selection system E11
E922 Engine overrun —
E924 Engine oil pressure lowering E11
E931 Abnormality in fuel control dial system E14
E934 Abnormality in engine water high temperature sensor system E15
E936 Abnormality in engine oil pressure switch system E15
E93C Abnormality in boost pressure sensor system E11
E93d Abnormality in fuel temperature sensor system E15
E954 Short circuit in starting switch C terminal system —
E955 Abnormality in engine controller network E0E
E956 Abnormality (1) in engine controller power source system E10
E957 Abnormality (2) in engine controller power source system E15
E95A Abnormality in engine controller fuel injection amount adjustment switch signal system —
E96A Abnormality in engine water low temperature sensor system E15
E970 Over current in fuel supply pump PVC1 system E11, E10 (Note2)
E971 Over current in fuel supply pump PVC2 system E11, E10 (Note2)
E974 Disconnection in fuel supply pump PVC1 system E11, E10 (Note2)
E975 Disconnection in fuel supply pump PVC2 system E11, E10 (Note2)
E977 Abnormality in common rail fuel pressure sensor system E11
E979 Abnormality (1) in common rail fuel high pressure E11

PC750, 800-6 20-147


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

Service code Abnormal system User code


E97A Abnormality (2) in common rail fuel high pressure E11
E97b Abnormality (1) in fuel supply pump no supply E11
E97C Abnormality (2) in fuel supply pump no supply E11
E97d Abnormality in common rail fuel pressure E11
E980 Abnormality in engine controller E11, E10 (Note3)
E981 Disconnection in No.1 fuel injector system E11, E10 (Note4)
E982 Disconnection in No.2 fuel injector system E11, E10 (Note4)
E983 Disconnection in No.3 fuel injector system E11, E10 (Note4)
E984 Disconnection in No.4 fuel injector system E11, E10 (Note4)
E985 Disconnection in No.5 fuel injector system E11, E10 (Note4)
E986 Disconnection in No.6 fuel injector system E11, E10 (Note4)
E98A Short circuit in No.1, 2, 3 fuel injector system E11, E10 (Note4)
E98b Short circuit in No.4, 5, 6 fuel injector system E11, E10 (Note4)

Note 1: If a single abnormality occurs, user code [E11] is displayed.


If the abnormality occurs at the same time in both the Ne rotation sensor and G rotation
sensor, user code [E10] is displayed.
Note 2: If a single abnormality occurs, user code [E11] is displayed.
If the abnormality occurs at the same time in both PCV1 and PCV2, user code [E10] is
displayed.
Note 3: If a single abnormality occurs, user code [E11] is displayed.
If the abnormality is serious and the controller all stop is generated, user code [E10] is
displayed.
Note 4: If a single abnormality occurs, user code [E11] is displayed.
If the abnormality occurs at the same time in another injector, user code [E10] is displayed.

fl Points to remember when carrying out troubleshooting


1) Points to remember if abnormality returns to normal by itself.
When carrying out troubleshooting of the failure, if the connector is disconnected and the T-
adapter is inserted, or if the T-adapter is removed and the connector is returned to its original
position, there are cases where the service code is no longer displayed or the monitor display
returns to normal. In such cases, the abnormality has probably returned to normal by itself.
However, there is a high probability that the same problem will occur again, so it is desirable
to follow up this problem carefully.
2) Handling service codes:
When displayed the abnormality code in memory and carrying out troubleshooting, note down
all the service codes on the display, then erase the display. After trying to re-enact the
problem, carry out troubleshooting according to the service code that is displayed.
fl Some of the service codes are cases where mistaken operation or abnormalities that occur
when the connector is disconnected are recorded by the memory function. Erasing the data
in this way saves any wasted work.
After completing troubleshooting, always erase the user code from memory.

20-148 PC750, 800-6


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

4. Monitoring code display function


The input signals from the sensors to engine
controller and the pump controller, and the out-
put signals to drive the solenoid can be checked
in real time with the monitoring code.
The methods of displaying the monitoring data
include items that are displayed as numerical
values, such as the engine speed, oil pressure,
voltage, or current, and items that are displayed
by bits, such as the actuation status of the oil
pressure switches or solenoids.
When the following operations are carried out,
the monitoring codes are displayed on the moni-
tor panel time display (1) and the monitoring
data are displayed on the service meter display
panel (2).
1) To switch to the monitoring code display
mode, keep the Time switch (3) + Heavy lift
switch (4) pressed for at least 2.5 seconds.
Example of display:
A (numerical display):
This shows the case when the engine
speed is displayed with monitoring code
[10].
B (bit display):
This shows the case when the S-NET
connection status is displayed with moni-
toring code [08].
2) To go on to the next monitoring code dis-
play, press the Time switch (3) + Working
mode right switch (5).
3) To go back to the previous code monitoring
code display, press the Time switch (3) +
Working mode left switch (6).
4) To finish using the monitoring code display
mode, keep the Time switch (3) + Heavy lift
switch (4) pressed for at least 2.5 seconds.

PC750, 800-6 20-149


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

Table 1 of monitoring codes (all codes)


fl For details of the displayed as “(6 bit)” in the Unit column, see the bit pattern chart.
Monitoring
code Item Unit Name of component
01 Monitor panel model selection code — Monitor panel
02 Pump controller model selection code — Pump controller
03 Engine controller model selection code — Engine controller
08 S-NET component connection status (6 bit) Monitor panel
10 Engine speed 10 rpm Pump controller
13 TVC output current 10 mA Pump controller
16 No.2 throttle command value 10 rpm Pump controller
20 Input status (1) of pump controller switch (6 bit) Pump controller
21 Input status (2) of pump controller switch (6 bit) Pump controller
22 Input status (3) of pump controller switch (6 bit) Pump controller
23 Drive status (1) of pump controller solenoid and relay (6 bit) Pump controller
24 Input status (1) of pump controller warning monitor sensor (6 bit) Pump controller
25 Input status (2) of pump controller warning monitor sensor (6 bit) Pump controller
26 Drive status (2) of pump controller solenoid and relay (6 bit) Pump controller
27 Input status (4) of pump controller switch (6 bit) Pump controller
32 Battery voltage 100 mV Pump controller
42 Fuel level sensor input voltage 10 mV Pump controller
43 Alternator (battery charge) input voltage 100 mV Pump controller
44 Hydraulic oil temperature sensor input voltage 10 mV Pump controller
47 Monitor panel output status (1) (6 bit) Monitor panel
48 Monitor panel input status (1) (6 bit) Monitor panel
49 Monitor panel input status (2) (6 bit) Monitor panel
4A Monitor panel input status (3) (6 bit) Monitor panel
4C Monitor panel output status (2) (6 bit) Monitor panel
50 Engine speed 10 rpm Engine controller
71 Acceleration opening 1% Engine controller
72 Fuel injection amount command mm3/st Engine controller
73 Common rail pressure command 1 MPa Engine controller
74 Fuel injection timing command 0.1 CA Engine controller
75 Common rail fuel pressure 1 MPa Engine controller
76 Boost pressure 1 kPa Engine controller
77 Engine water temperature (high temperature sensor) 1°C Engine controller
78 Engine water temperature (low temperature sensor) 1°C Engine controller
79 Fuel temperature 1°C Engine controller
80 Engine controlled mode — Engine controller
81 Conversion torque (Load output) 1% Engine controller
82 Fuel control dial input voltage 10 mV Engine controller
83 Right fuel injection amount adjustment switch (ROT-SW1) — Engine controller
84 Left fuel injection amount adjustment switch (ROT-SW2) — Engine controller
85 Engine controller input status (6 bit) Engine controller
C0 Monitor panel program version — Monitor panel
C1 Pump control program version — Pump controller
C2 Engine controller program version — Engine controller

20-150 PC750, 800-6


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

Table 2 of monitoring codes (details of bit pattern


code)
fl Bits (1) to (6) in the diagram on the right light
up or go out to display the monitoring data.

Monitoring Item Bit Details (status when bit is lighted up)


code No.
(1) Pump controller connected
(2)
S-NET component connection (3) Engine controller connected
08
status (4)
(5)
(6)
(1) Swing PPC pressure switch ON
(2) R.H. travel PPC pressure switch ON
Input status (1) of pump (3) Boom RAISE PPC pressure switch ON
20 (4) Boom LOWER PPC pressure switch ON
controller switch
(5) Arm IN PPC pressure switch ON
(6) Arm OUT PPC pressure switch ON
(1) Bucket CURL PPC pressure switch ON
(2) Bucket DUMP PPC pressure switch ON
(3) Swing lock switch ON
21 No.2 throttle command value
(4) Servce PPC pressure switch ON
(5) L.H. travel PPC pressure switch ON
(6) Swing holding brake release switch ON
(1) Model selection signal 1 GND connected
(2) Model selection signal 2 GND connected
Input status (3) of pump (3) Model selection signal 3 GND connected
22 (4) Model selection signal 4 GND connected
controller switch
(5) Kerosene mode input GND connected
(6) Left knob switch ON
(1) CO cancel solenoid ON
(2) Straight-travel solenoid ON
Drive status (1) of pump (3) Swing holding brake solenoid ON
23 (4) 2-stage relief solenoid ON
controller solenoid and relay
(5) Swing priority selector solenoid ON
(6) Travel speed solenoid ON
(1) Step light switch OFF
(2) Horn switch OFF
Input status (1) of pump
(3) Coolant level sensor OPEN (low level detected)
24 controller warning monitor
(4) Engine oil level sensor OPEN (low level detected)
sensor
(5) Hydraulic oil temperature sensor OPEN (high temperature detected)
(6) Air cleaner clogging sensor OPEN (clogging detected)

PC750, 800-6 20-151


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

Monitoring Item Bit Details (status when bit is lighted up)


code No.
(1)
(2) Overload sensor OPEN (option)
Input status (2) of pump
(3)
25 controller warning monitor
(4)
sensor
(5) Automatic greasing controller abnormal (option)
(6)
(1) Flash light relay: Actuated
(2) Step light relay: Actuated
Drive status (2) of pump (3) Auto-deceleration signal: Output
26
controller solenoid and relay (4) Step light power source keeping relay: Actuated
(5)
(6)
(1) Model selection signal 5 GND connected
(2)
Input status (4) of pump (3)
27
controller switch (4) Starting switch C signal ON (turn switch to START)
(5) Starting switch ACC signal ON (turned switch to ON)
(6)
(1)
(2) Alarm buzzer OFF
(3) Wiper motor drive ( R) OFF
47 Monitor panel output status (1)
(4) Wiper motor drive (L) OFF
(5) Window washer drive OFF
(6)
(1) Wiper and washer switch ON: When OFF
(2) Wiper and washer switch INT: When OFF
(3) Wiper and washer switch WASHER: When OFF
48 Monitor panel input status (1)
(4) 1Window limit switch OPEN
(5) Limit switch W OPEN
(6) Limit switch P OPEN
(1) Starting switch ACC signal OFF (turn switch to OFF)
(2) Starting switch BR signal: When high voltage
(3) Lamp switch ON
49 Monitor panel input status (2)
(4) Pre-heater switch ON
(5) Starting switch C signal: Sometimes turns ON
(6)
(1) Clock switch ON
(2) PPC oil pressure selector switch OFF
(3) Overload selector switch OFF
4A Monitor panel input status (3)
(4)
(5) Swing lock switch OFF
(6) Buzzer cancel switch OFF
(1)
(2) Wiper motor forward rotation relay output: When OFF or voltage is abnormal
(3) Wiper motor reverse rotation relay output: When OFF or voltage is abnormal
4C Monitor panel output status (2)
(4) Washer motor drive output: When OFF or voltage is abnormal
(5)
(6)

20-152 PC750, 800-6


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

Monitoring Item Bit Details (status when bit is lighted up)


code No.
(1) Starting switch C signal ON (turn switch to START)
(2) Auto-deceleration signal GND connected
(3) Model selection signal 1 GND connected
85 Engine controller input status
(4) Model selection signal 2 GND connected
(5) Model selection signal 3 GND connected
(6)

5. Setting function for reduced cylinder mode


operation
This is used when setting the engine to reduced
cylinder mode operation.
fl For details, see INSPECTION & MAINTE-
NANCE, Reduced cylinder mode operation
for engine.
With the following operation, the engine speed
can be displayed on time display (1) of the moni-
tor panel and the cylinder number can be dis-
played on service meter display (2).
fl The engine speed is displayed in units of 10
rpm.
fl It is possible to set the reduced cylinder
mode operation for a single cylinder or mul-
tiple cylinders.
1) To switch to reduced cylinder mode opera-
tion:
Keep time switch (3), R.H. travel speed switch
(4), and R.H. working mode switch (5)
pressed at the same time for at least 2.5
seconds.
2) To select the cylinder to set or cancel for
reduced cylinder mode operation:
Keep time mode switch (3) pressed and press
R.H. working mode switch (5) or L.H. work-
ing mode switch (6).
3) To set or cancel reduced cylinder mode op-
eration:
Keep time switch (3) pressed and press
heavy lift switch (7).
4) To finish reduced cylinder mode operation:
Keep time switch (3), R.H. travel speed switch
(4), and R.H. working mode switch (5)
pressed at the same time for at least 2.5
seconds.

PC750, 800-6 20-153


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

6. Setting function for working mode default and


swing priority mode
The working mode on the monitor panel is set
so that normally the H mode lights up and the
swing priority mode foes out when the starting
switch is turned ON.
If the function for setting the default is used as
follows, it is possible to change the setting so
that the system starts with the working mode
and swing priority mode desired by the opera-
tor.
1) To switch to the default setting mode:
Keep time switch (1) and R.H. working mode
switch (2) pressed at the same time for at
least 2.5 seconds.
fl When the system enters the default set-
ting mode, the working mode LED
flashes.
(The swing priority mode LED remains
OFF.)
2) To change the setting of the working mode
default:
Press L.H. working mode switch (3) or R.H.
working mode switch (2) to make the LED of
the desired working mode flash.
3) To turn the swing priority mode ON when
the starting switch is ON:
Press swing priority mode switch (4) and
make the LED of the swing priority mode
flash.
4) To return the swing priority mode to OFF
when the starting switch is ON:
Press swing priority mode switch (4) again
and turn the LED of the swing priority mode
off.
To finish using the default setting mode:
Keep time switch (1) and R.H. working mode
switch (2) pressed at the same time for at
least 2.5 seconds.
To check after changing the default setting:
Turn the starting switch OFF, then turn it
ON again and check the LED of the working
mode switch.

20-154 PC750, 800-6


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

7. Setting function for oil maintenance display


On machines equipped with the oil maintenance
function, the oil maintenance display is given
from 10 hours before the set oil change time
until it is reset.
For 20 seconds after the starting switch is turned
ON, oil maintenance lamp (1) lights up, the
elapsed time is displayed on service meter dis-
play (2), and then the telephone number is dis-
played on time display (3) and service meter
display (2).
With the oil maintenance function, it is possible
to set, change, or cancel the display, or to set,
change, or cancel the telephone number.
Example: When the oil change interval is set to
250 hours, the following are displayed.
• Time elapsed after oil change: 245 hours
• Telephone number: 0123456789
fl Nothing is displayed for the elapsed time
until it reaches 10 hours before the change
interval.
To check the elapsed time in this condition,
keep buzzer cancel switch (4) pressed and
turn the starting switch ON. The elapsed time
is displayed for 10 seconds.
fl The telephone number is not displayed if no
telephone number has been set.
fl If the telephone number has been set, when
the starting switch is turned ON, the elapsed
time is displayed for 10 seconds, and then
the telephone number is displayed for 10
seconds. After that, the display switches to
the normal display.
If no telephone number has been set, the
elapsed time is displayed for 20 seconds af-
ter the starting switch is turned on, and the
display then switches to the normal display.
1) To set the interval:
i) Keep time switch (5) and swing priority
mode switch (6) pressed at the same time
for at least 2.5 seconds to switch to the
interval setting mode.
ii) Press buzzer cancel switch (4) to set the
time for the interval.
Example: When interval 250 hours is se-
lected

PC750, 800-6 20-155


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

iii) Keep time switch (5) and swing priority


mode switch (6) pressed at the same time
for at least 2.5 seconds to finish the in-
terval setting mode.
fl Interval display
- - - h: Default mode (oil maintenance
function not set)
125h: Interval is set for every 125 hours
250h: Interval is set for every 250 hours
500h: Interval is set for every 500h hours
dh : Demo mode is set
ª If the demo mode is used, a demonstra-
tion of the oil maintenance function can
be carried out when the machine is de-
livered.
The following functions can be carried
out in the demo mode.
(1) Elapsed time display (this is for dem-
onstration purposes only, so the
elapsed time is fixed at 240h)
(2) Telephone number display (the tele-
phone number must be input before
using the demo)
(3) Resetting elapsed time
After setting to the demo mode, turn
the starting switch OFF, and then turn
it ON again to start the demonstra-
tion.
After setting the demo mode, it can
be carried out four times. After that,
it is automatically canceled.
2) Resetting elapsed time after changing oil
Press buzzer cancel switch (4) and keep it
depressed for 3 seconds while the monitor
panel is giving the oil maintenance display.
The elapsed time will be reset and the dis-
play [Elapsed time: 0h] will be given for 1
second.
3) To set or correct telephone number:
i) Keep time switch (5) and auto-decelera-
tion switch (7) pressed at the same time
for at least 2.5 seconds to switch to the
telephone number mode.

20-156 PC750, 800-6


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

ii) Press time switch (5) and L.H. working


mode switch (8) or R.H. working mode
switch (9) to select the number to be set
or corrected.
fl Two digits are chosen at the same
time for the number.
fl When the display of the telephone
number is canceled, all numbers are
set to [0].
iii) Press time switch (5) and L.H. travel
speed switch (10) and select the num-
bers on the left.
iv) Press time switch (5) and R.H. travel
speed switch (11) and select the num-
bers on the right.
v) Keep time switch (5) and auto-decelera-
tion switch (7) pressed at the same time
for at least 2.5 seconds to finish the tele-
phone number mode.

8. Adjustment function for time display


When setting the time on the time display, do
as follows.
1) When correcting time manually:
i) Keep time switch (1) pressed for at least
2.5 seconds to switch to the time adjust-
ment mode.
ii) Press L.H. working mode switch [H] (2)
to adjust the hours; press R.H. working
mode switch [M] (3) to adjust the min-
utes.
fl If the switch is kept pressed for at
least 2.5 seconds, the numbers ad-
vance rapidly.
iii) Keep time switch (1) pressed for at least
2.5 seconds to finish the time adjustment
mode.
2) When correcting hour according to time sig-
nal:
i) Keep time switch (1) pressed for at least
2.5 seconds to switch to the time adjust-
ment mode.
ii) Press L.H. working mode switch [H] (2)
to adjust the hours; press R.H. working
mode switch [M] (3) to adjust the min-
utes to prepare to set according to the
time signal.

PC750, 800-6 20-157


TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

fl When setting according to the time


signal, if the minute display is 14
minutes or less, the time will return
to 0 minutes; if the minute display is
45 minutes or more, the time will
advance to 0 minutes and the hour
will advance by 1.
When preparing to set according to
the time signal, set the minute dis-
play to either less than 14 or more
than 45.
iii) When the time signal sounds, press
heavy lift switch (4).
iv) Keep time switch (1) pressed for at least
2.5 seconds to finish the time adjustment
mode.

20-158 PC750, 800-6


TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE

METHOD OF USING JUDGEMENT TABLE


This judgement table is a tool to determine if the problem with the machine is caused by an abnormal-
ity in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms
are then used to decide which troubleshooting table (E– , C– , F– , H– , M– ) matches
the symptoms.
The judgement table is designed so that it is easy to determine from the user code and service code
which troubleshooting table to go to.
fl The abnormality display (warning) given by the monitor panel leads directly to troubleshooting of
the machine monitor (M– ). (See troubleshooting of the machine monitor system)
1. When using judgement table for engine throttle, pump controller (governor control system) and
engine related parts
• If a service code is displayed on the monitor panel, go to the troubleshooting code at the
bottom of the judgement table (E– ).
(A ● mark is put at the places where the failure mode and service code match.)
• If a problem has appeared but no service code is displayed on the monitor panel, go to the
point where the failure mode matches the troubleshooting code on the right of the judgement
table (E– or refer to engine shop manual “140-3 Series”).
<Example> Failure mode “Engine does not start”.
Procedure: Check if the service code is being displayed on the monitor panel.
Self-diagnostic display Self-diagnostic display
Abnormality in engine oil pressure switch system
Abnormality in engine Ne rotation sensor system

Abnormality in engine water temperature (low- temperature) sensor system

Short circuit in No. 1, No. 2, No. 3 fuel injector system


Short circuit in No. 4, No. 5, No. 6 fuel injector system
Abnormality in fuel injection amount adjustment switch signal
Abnormality in engine water temperature (high- temperature) sensor system

Disconnection in fuel supply pump PCV1 system


Disconnection in fuel supply pump PCV2 system
Abnormality in common rail fuel pressure sensor system
Abnormality in machine model selection system
Abnormality in engine G rotation sensor system

Abnormality in fuel temperature sensor system


Short circuit in starting switch C signal system

Overcurrent in fuel supply pump PCV1 system


Overcurrent in fuel supply pump PCV2 system

Common rail fuel high-pressure abnormality 1


Common rail fuel high-pressure abnormality 2
Abnormality in boost pressure sensor system

Supply pump non-force feed abnormality 1


Supply pump non-force feed abnormality 2

Disconnection in No. 1 fuel injector system


Disconnection in No. 2 fuel injector system
Disconnection in No. 3 fuel injector system
Disconnection in No. 4 fuel injector system
Disconnection in No. 5 fuel injector system
Disconnection in No. 6 fuel injector system
Abnormality in common rail fuel pressure
Abnormality in fuel control dial system

Power source system abnormality 1


Power source system abnormality 2
Abnormality in network system
Drop in engine oil pressure

Abnormality in controller
Troubleshooting code
when no service code
is displayed

Does starting motor turn?


Overheat

Overrun

User code E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11
— E10 E10 E11 — E11 E14 E15 E15 E11 E15 — E0E E10 E15 — E15 E10 E10 E10 E10 E11 E11 E10 E11 E10 E11 E10 E10 E10 E10 E10 E10 E10 E10 E10
Service 108 91b 91C 920 922 924 931 934 936 93C 93d 954 955 956 957 95A 96A 970 971 974 975 977 979 97A 97b 97C 97d 980 981 982 983 984 985 986 98A 98b
code
No. Failure mode
1 Engine does not start ‡ ‡ ‡ ‡ ‡‡ ‡ ‡‡‡ ‡ See engine volume

2
Starting ability Exhaust gas is emitted but engine does not start, or is difficult to start ‡ ‡ ‡ ‡‡‡ ‡ ‡‡ ‡ See engine volume
is poor No exhaust gas is emitted ‡ ‡ ‡ ‡ ‡
3 Engine stops during operation ‡ ‡ ‡ ‡ ‡ ‡‡ ‡ ‡ ‡ ‡ ‡‡ ‡ See engine volume
4 Lack of engine output ‡‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡‡ ‡ ‡ ‡‡‡ ‡ ‡‡ ‡
5 Acceleration is poor ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡‡ ‡
6
Engine speed stays at
low idling, and does not
Exhaust gas is normal ‡ ‡ ‡ ‡ ‡
follow fuel control dial Exhaust gas is extremely black See engine volume
Accelerates at high Accelerated at same time as abnormality display appeared
7
idling Accelerated while abnormality display was being displayed

8
Low idling does not
work according to
Does not switch to low idling ‡ ‡ ‡
operation Does not switch to high idling ‡ ‡ ‡ ‡
Fuel consumption is Exhaust gas is normal See engine volume
9
excessive Exhaust gas is extremely black

10
High idling does not Does not rise to high idling
work according to
‡ ‡ ‡ ‡‡‡ ‡ ‡‡ ‡
operation Switches to high idling but returns to low idling ‡ ‡
11 Warming-up operation is defective ‡ ‡ ‡ ‡
12 Auto-deceleration does not work ‡
13 Engine speed does not change even when working mode is switched ‡
Engine does Engine remains accelerated See engine volume
14
not stop Remains at low idling even when starting switch is turned OFF
15 There is hunting of engine (low idling speed is irregular) ‡ See engine volume
16 Oil consumption is excessive, or exhaust gas is blue See engine volume
17 Oil becomes dirty prematurely See engine volume
18 Oil is mixed in coolant See engine volume
19 Engine oil pressure caution lamp lights up ‡ See engine volume
20 Oil level rises See engine volume
21 Coolant temperature rises too high ‡ See engine volume
22 Abnormal noise is generated ‡ ‡‡‡ ‡ ‡‡ ‡
23 There is excessive vibration ‡ ‡‡‡ ‡ ‡‡ ‡
Troubleshooting M-4 E-1 E-2 E-3 E-4 E-5 E-6 E-7 E-8 E-9 E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 E-20 E-21 E-22 E-22 E-23 E-23 E-24 E-25 E-26 E-27 E-28 E-29 E-30 E-31 E-32 E-33
code

[Judgement]
1) If a service code is being displayed on the monitor panel ..... go to troubleshooting [E9: ] for
the engine controller.
2) If no service code is displayed on the monitor panel, and the engine does not start:
Starting motor rotates .................. Go to troubleshooting engine
shop manual “140-3 Series”
• Check that starting
motor rotates
Starting motor does not rotate ... Go to troubleshooting E-8 of
electrical system

PC750, 800-6 20-159


TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE

2. When using judgement table for pump controller and hydraulic related parts
• If a service code is displayed on the monitor panel, go to the troubleshooting code at the
bottom of the judgement table (C– ).
(A ● mark is put at the places where the failure mode and service code match.)
• If a problem has appeared but no service code is displayed on the monitor panel, go to the
point where the failure mode matches the input signal, and check the display for the input
signal (the display at the place with a mark).
• If it is displayed normally, go to the troubleshooting code on the right of the judgement
table (H– ).
• If the input signal is not displayed on the monitor panel, go to the troubleshooting code at
the bottom of the judgement table (F– ).

<Example> Failure mode “Upper structure does not swing”.


Procedure: Check if the service code is being displayed on the monitor panel.

fl If service code E218 (abnormality in network system) is displayed, go to troubleshooting for N mode.
Pump controller (E2:XX system) Pump controller (E2:XX system) Check items in monitoring mode
Parts causing failure Self-diagnostic display Oil pressure switches Solenoid drive condition
Self-diagnostic display

Disconnection in 2-stage relief solenoid system

Disconnection in swing priority solenoid system


Short circuit in travel speed solenoid system
Short circuit in swing holding brake solenoid system

Disconnection in straight-travel solenoid system

Short circuit in 2-stage relief solenoid system

Disconnection in travel speed solenoid system

Abnormality in engine speed sensor system


Disconnection in CO cancel solenoid system

Short circuit in swing priority solenoid system


Short circuit in straight-travel solenoid system
Disconnection in swing holding brake solenoid system
Short circuit in CO cancel solenoid system
Abnormality in controller power source

Disconnection in TVC solenoid system


Short circuit in TVC solenoid system

Troubleshooting code if no

Model selection input error


service code is displayed

Swing holding brake


Swing lock switch

Machine push-up solenoid


Engine speed input
TVC current output

Boom shockless solenoid


Boom LOWER

Straight travel

Swing priority