‘SEBM001302 SHOW IMLA\IN TU AIL KOMATSU PC/3UU-2 MACHINE MODEL SERIAL No. PC75UU-2 5001 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 re- quire. Materials and specifications are subject to change without notice. + PC75UU-2 mount the 4D95L-1 engine. For details of the engine, see the 95 Series Engine Shop Manual. © 2000 KOMATSU All Rights Reserved 00-1 Printed in Japan 09-00(02) ®01 10 20 30 40 CONTENTS GENERAL 0c STRUCTURE AND FUNCTION .... TESTING AND ADJUSTING................... DISASSEMBLY AND ASSEMBLY ... MAINTENANCE STANDARD No. of page esses O11 ese 10-1 20-1 30-1 PC75UU-2‘The affected pages are indicated by the use of the following marks. It is requested that necessary |_Mark seston Action required actions be taken to these pages according to the © | Page tobe newly added| add table below. @ | Page tobe replaced | Replace (_} | Page to be deleted Discard Pages having no marks are those previously revised or made additions. LIST OF REVISED PAGES Man Pose Revision! wank Page Revision] man rage Revtion| won rage RHOT tan page Revton © 00-1 10:3 20-36 20-79 20-123 00-2 10-4 20-37 20-80 20-124 © 00-21 105 20.38 20-81 20-126 © 00-22 10-6 20-39 20-82 20-127 00-3 10-7 20-40 20-83 20-128 00-4 20-81 20-84 20-129 00-5 201 20-42 20-85 20-131 00-6 20-2 20-43, 20-86 20-132 00-7 20-3 20-44 20-87 20-133 00-8 20-4 20-45 20-88 20-134 00-9 20-5 20-46 20-89 20-135 00-10 20-6 20.47 20-80 20-136 00-17 20-7 20-48 20-91 20-137 00-12 20-8 20-49 20-93 20-138 00-13 20-9 20-50 20-94 20-139 00-14 20-10 20-52 20.95 20-140 00-15 20-11 20-53 20.97 20-141 00-16 20-12 20-55 20.99 20-142 00-17 20-13 20-56 20-100 20-143 00-18 20-14 20-87 20-101 20-144 00-19 20-15 20-58 20-102 20-145 00-20 20-16 20-58 20-103 20-146 00-21 20-17 20-60 20-104 20-148 00-22 20-18 20-61 20-105 20-149 20-19 20-62 20-108 20-150 O11 @ 20-20 20-63, 20-107 20-151 12 © 20-21 20-64 20-108 20-152 13 @ 20-22 20-65 20-109 20-153 14 = @ 20-23 20-66 20-110 20-154 5 @ 20-24 20-67 20-111 20-155 16 6 20-25 20-68 20-112 20-156 17 @ 20-28 20-69, 20-113 20-157 18 20-27 20-70 20-114 20-158 19 @ 20-28 20-71 20-115 20-159 01-10 @ 20-29 20-72 20-116 20-160 on @ 20-30 20-73, 20-117 20-161 0112 @ 20-31 20-74 20-118, | 20-162 01-13 «® 20-32 20-75 20-119 | 20-163 20-33 20-76 20-120 20-164 104 20-34 20-77 20-121 20-165 10-2 20-35 20-78 20-122 20-166 PC7SUU-2 0-2-1Mak Page Revtor] Man Page RevitOn! mark Page Revlon! mane age REvGON| Wark Page Revision 20-167 © 30-434 @ | 0 3081-10@ 30-130 @ © 30435 ® | o 3081-11 @ 30-131 © e301 @ | 0 30436 @ | o 3081-120 30-132 @ © 302 @ | o 3047 @ | o 3081-13@ 30-133 @ 303 @ | o 30438 @ | o 3081-14@ 30-134 @ 30-4 =@ | o 30439 @ | o 3081-15 @ 30-135 @ 305 @ | 0 304310@ | « 3082 @ © 07 @ 30-46 © 3083 @ 40-1 208 @ 30-45 © 30-84 40-2 ° 309 @ 30-46 @ 3085 © 40-3 ° 3091 @ 30-47 @ 3086 @ 40-4 0 3092 @ 30-48 @ 3087 @ 40-5 ° 3093 @ 3049 @ 30-88 © 40-6 o 3094 @ 30:50 @ 3089 40-7 © 3095 @ 3051 @ 30-90 40-8 © 3096 @ 3052 © 3091 @ 40-9 o 3097 @ 3053 @ 3092 @ 40-10 2 3010 © 3054 @ 3083 @ 40-11 30-11 3055 @ 30:94 @ 40-12 30-12 3056 © 30:95 @ 40-13, 30-13 @ 3057 @ 30.96 © 40-14 30-14 32058 @ 3097 @ 40-15 30-15 3059 @ 30-98 @ 40-16 3016 O 30-60 © 3099 40-17 3017 @ 3061 @ 30-100 @ 40-18 30-18 @ 3062 @ 30-101 @ 40-19 30-19 @ 3063 «© 30-102 @ 40-20 3020 @ 3064 @ 30-103 @ 40-21 30-21 3065 @ 30-104 @ 40-22 30-22 3066 @ 30-105 40-23 30-23 30-67 @ 30-106 © 30-24 © 30-68 @ 30-107 30-25 @ 320-69 @ 30-108 @) 30-26 @ 30-70 @ 30-109 @ 30-27 @ 30.71 @ 30-110 @ 30-28 @ 30-72 @ 320-111 © 30-29 @ 3073 @ 30-112, O 30:30 @ 3074 @ 30-113 @ 3031 © 30-75 @ 30-114 © 30.32 @ 320-76 @ 320-115 © 30.33 @ 3077 @ 320-116 @ 3034 @ 320-78 @ 30-117 © 30:35 © 30-79 @ 30-118 3036 @ 3080 @ 30-119 3037 @ 3081 @ 30-120 30:38 @ | o 30811 @ 30-121 © 30:39 @ | 0 30812 @ 30-122 @ 30-40 @ | 0 30813 @ 30-123 @ 30-41 @ | 0 3081-4 @ 30-124 30-42 @ | 0 30815 @ 30-125 @ 30-43 «@ | 0 30816 @ 30-126 @) © 30-481 ® | o 30817 @ 30-127 © 30432 @ | o 30818 © 30-128 O © 30433 @ | o 30819 @ 30-128 @ 00-2-2 PC7SUU-2Ay important SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in tl manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to worker: , the symbol A is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed care. fully. if any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing # Always wear safety glasses when hitting Parts with a hammer. * Always wear safety glasses when grinding parts with a grinder. etc 3.If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work 4. When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment 5.Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for ‘smoking. Never smoke while working, PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving 8 Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them 9. When disassembling or assembling, sup- port the machine with blocks, jacks of stands before starting work 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine, If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing 00-3PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before car- rying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first. 14,When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil ‘on the floor can cause you to slip, or can even start fi 18. As a general rule, do not use gasoline to wash parts. In particular, use only the mit mum of gasoline when washing electrical parts. 00-4 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. When installing hoses and wites, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely ca ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21, When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or Parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand, Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the trackFOREWORD This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of ‘components; these chapters are further divided into the following sections, STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting 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” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE ‘ations contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES ‘Shop manuals are issued as a guide to carry- ing out repairs. They are divided as follows: Chassis volume: Issued for every machine model Issued for each engine series Each issued as ‘one volume to cover all models Engine volume: Electrical volume Attachments volume ‘These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is neces- sary that chassis, engine, electrical and attach- ment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up-to-date information before you start any work FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples shows how to read the page number. Example 1 (Chassis volume) 10-3 Item number (10. Structure and Function) Consecutive page number for each item, Example 2 (Engine volume): 12-410 Unit number (1. Engine) tem number (2. Testing and Adjusting) Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are i dicated 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 10-4-2 1 Added pages —C 19.203-2 10-5 12-204 00-6 REVISED EDITION MARK ()@@-~) ‘When a manual is revised, an edition mark is, recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol | ltem Remarks Special safety precautions are necessary when performing the work, A J seew ‘Special technical precautions fr other precautions for preserving standards are necessary when performing the work | caution Weight of parts or systems. Caution necessary when Weight | selecting hoisting wire, or when working pasture is important, ete Places that require special S|, [ishter | attention for the tightening 19 tordue| torque during assembly. Places to be coated with am Coat | adhesives and lubricants, etc. Places where oil, water or Oil, water | fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained, wel | DrainHOISTING INSTRUCTIONS. HOISTING INSTRUCTIONS Ay Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and Assembly section, every part weigh- ing 25 kg or more is indicated clearly with the symbol (5 1.If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: * Check for removal of all bolts fastening the part to the relative parts. * Check for existence of another part causing interference with the part to be removed. 2. Wire ropes 1)Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “2” or “S” twist ropes without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 1.0 112 14 125 16 14 22 16 28 18 3.6 20 44 224 56 30 10.0 40 18.0 50 28.0 60 40.0 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, Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion, 100% 88% 7%) Mag 3)Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. By Singing with one rope may cause turning of the load during hoisting, untwisting of the rope. or slipping of the rope from its original winding Position on the load, which can result in a dangerous accident. 4)Do not sling a heavy load with ropes forming @ wide hanging angle from the hook. When hoisting @ load with two or more Fopes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150° A ve Ea 2 & i ae Ltn agi soosSTANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of "Disassembly and Assembly”. Thread diameter width of bolt across flat (nm) eam) kgm Nm 6 10 1.354015 13.2414 8 13 3.2+03 31.4429 10 7 6.7407 65.7+68 12 19 11.5+10 112+98 14 22 18.0420 177419 16 24 28543 27929 18 27 3924 383439 20 30 56+6 549+58 22 32 76+8 74578 24 36 945+10 927+98 27 a 135+15 1320140 30 46 175+20 1720+ 190 33 50 225%25 2210240 36 55 280+30 2750+ 290 39 60 335435 32804340 oui 1 This torque table does not apply to the bolts with which nylon packings or other non- ferrous metal washers are to be used, or which require tightening to otherwise specified torque. * Nm (newton meter): 1Nm = 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Width Tightening torque across flats ————— (mmm) kgm 7 Nm 67+07 65.7+68 11551 112498 279+29 Thread diameter ‘of bolt (mm) 10 12 00-8STANDARD TIGHTENING TORQUE Seating surtace 3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared. f= 0088 Thread diameter | Width across flats Tightening torque ‘of nut part ‘of nut part (com) (me) Nm 245+4.9 494196 785+196 13734294 1765+29.4 196.1+49 245.249 294.2449 COATING MATERIALS = The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenclature Komatsu code ‘Applications. Used to apply rubber pads, rubber gaskets, and cork plugs. ‘Used to apply resin, rubber. metalic and on-metalic parts when 3 Adhesives ue Preventing bolts, auts and plugs from loosening and leaking oi, Provides an awight, electrically insulating seal Used for aluminum surtace Used'o cost pugs plate shaped, bowl shaped] and holes, and mating portion of shaft Used with gaskets and packings to increase sealing effect. emcee [ea] Used’by itself on mounting surfaces on the final drive and Wansmission cases. (Thickness after ightening. 0.07 ~ 0.08 rm) ‘Used by iseif to seal grease fitings, tapered screw Fit /araune circuits of ese than 80 mm inge ond apered Silicon base type used in combinaton with LG-1 and LG-4. Has a shorter curing time than G-6, and easier to peeloft, ‘Applied to bearings and taper shafts to facilitate pr prevent sticking, burning or rusting, "Antfaction compound {Lubricant including molybdenum disulfide) Grease. {ithwum grease? oz “Rpplied to bearings. siding paris and ol seals Tor lubrication, rust [prevention and factitahon of assembling work Vaseline — Used for protecting battery electrode terminals from corrosion. *LT-2 is also called LOCTITE in the shop manuals. 00-9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: SWB indicates a cable having a nominal number 5 and white coating with black stripe. CLASSIFICATION BY THICKNESS Seance m| tne oes | O82 O88 Za | 12] Startna, baring soralete 2 26 oa Z08 3a 20 | taming. sonal ete 5 os 082 328 a6 37 | cheraing and Sanat 75 ee 04s 7336 70 59] Staring (ow pig 70 3 080 wars | ne 135 | String 3 a7 080 wae | 196 178 | Stina 100 a7 080 | 1081 176 z20___| Storing CLASSIFICATION BY COLOR AND CODE » Circuits . er cram | owe | stan | tghiog | nstument | Sat w = 3 ae ' wnie [Bick te Yaow | Geen tie wa = Taw a ow ? Color] White & Red - Red & White | Yellow & Red | Green & White Coe] we = 7 ve om ir © | one| Color] wnies acc | — [aa avetow| Aevaaacr [Votow@ Buck] Goons Rea | Bund fea cose] we = aR ww ve wr 7 ‘ Color] wnte @Bie | | @iackeAed | Revd Votow | velow & Green Green Yetow | Bue &Vetow Coase = = 7 * or or 6 Color] White & Green| — Red & Green | Volow &Bive [Green &Blocd | ie & Bock) Toael = = m ww Cy = ® Color = = fe Red & Blue | Yellow & White| (Green & Blue) = 00-10CONVERSION TABLE CONVERSION TABLE Method of using the Conversion Table ‘The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below Example + Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches (1) Locate the number 50 in the vertical column at the left side, take this as @), then draw a horizontal tine trom @) {2) Locate the number § in the row across the top, take this as @, then draw a perpendicular line down trom ©) (3) Take the point where the two lines cross as ©). This point © gives the value when converting from millimeters to inches. Therefore, 85 mm = 2.165 inches. 2. Convert 550 mm into inches, (1) The number $50 does not appear in the table, so divide by 10 (move the decimal poi to the left) to convert it to 55 mm (2) Carry out the came 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 one place Millimeters to inches ® 1mm > 0.03997 in ee ee ° 0038 | 0079 | ora | 0157 0236 | 0276 | 0315 | 0254 10 | 0398 | 0433 | 0472 | 0812 | 0581 0630 | 0669 | 0709 | o748 20 | 0787 | 0827 | 0866 | 0906 | 094s voza | 1063 | 1102 | 1142 30, | 1181 | 1.220 | 1260 | 1299 | 1339 1417 | 1457 | 1496 | 1536 40 | 1575 | 1614 | 1654 | 1693 | 1732 reit | 1850 | 1890 | 1929 |.2126 |[2165]] 2208 | 2244 | 2263 | 2323 0 | 2869 | 2598 | 2638 | 2677 | 2717 | 2756 | 2795 | 2035 | 2e74 | 2913 | 2953 | 2992 | 3032 | 3071 | 3110 | 3150 | 3189 | 3228 | 3268 | 3307 | 3346 | 3386 | 3.425 | 3465 | 3504 3543 | 3583 | 3622 | 3661 | 3701 | 3740 | 3780 | sero | 3ese | 3008 00-11CONVERSION TABLE Millimeters to Inches 1 mm = 0.03937 in o |: | 2 | 3 | ] I 19 | eas | 04a | 042 | 012 | ossi | oss: | ox ose | 0709 ores 20 0787 0827 | 0866 | 0906 | 0965 | o9es 1.02 | 1059 102 | 1.42 30 ej 12720 | 1260 | 1.209 | 1.339 | 1.378) 1417 1457 | 1496 1.536 40 575 sie | ese ass 7a2 | 1772 vert 1.860 1890 920 | | : | | so | v9.00 | 208 | 2087 | 2087 | arze | oases | 2205 2204 | 2280 2222 6 2362 2402 2481 | 2480 | 2520 | 2569 2598 | 2638 | 2677, 2.717 80 3160 3189 | 3228 3.268 | 3307 | 2346 33986 3425 3.465 3.504 co | ssea asa | acre 26er | ayo 2740 | 2700 2010 | 3050 2008 1 Kilogram to Pound 1 ha = 2.2046 10 | | ] ] ] T T weet lefe[-lefeleiels —— 220 | “aa1 | 661 | gez | 102! 1323! 1543) 1764 1984 10 2205 | 2425 | 2646 | 2066 2086 3307 95.27 | 3748! 3968 41.89 20 44.09 46.30 48.50 : 50.71 | 51.91 66.12) 57.32, 5953 ' 61.73 6393 20 66.14) 6836 7056 7275 | 7495 1716 | 7937 | 8157 8378 8598 40 8.18 90:39 9259 9480 97.00 99.21 | 101.41 | 10362 10582 10803 EM ree (reed se) os) rere eed rece) eet eed or 0 | 192.28 | 13448 13669 | 138.89 | 141,10 | 149.30 | 14551 1147.71 | 14991 | 15:12 70 |194:32 | 15659 15873 | 160.94 163.14 - 165.95 , 16755 169.76 171.96 174.17 80 176.37 | 17857 180.78 | 18298 | 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 1 i i 4 1 1 00-12CONVERSION TABLE Liter to U.S. Gallon 1 &= 0.2642 US. Gal T T 1 ] TY. o |} 1 2 | 3 4) 5 6? i 9 | | | sos | | zee} osae| 0793 | 1057) 121) 1585/ teeo! 2113) 2370 10 | zee] 2908] 3.170] s4a4 | 3.000] 2960) 4227. 4401} 4755] so19 20 5283 5548) 5612| 6076) 6340| 6608] 6859) 7139 7397| 7.661 40 10567 po est too 11.359 | 11.624 11.888 | 12.152 | 12416 | 12.680 | 12.944 a | | so | 13208 | 13473 | 13737 | 14001 | 14265 | 14529 | 14795 | 15058 | 15322 15.586 co | 5.880 | 16115 | 16379 | 16643 | 16907 | 17.471 | 17435 | 17700 17964 18.228 10 18.492 | 18.756 | 19.020 | 19.265 | 19.549 | 19813 20077 20381 | 20605 | 20870 wo | arise som a ||| 22.719 | 22983 | 23247 23511 0 23.75 | 24040 | 24.304 | 24.568 | 24.832 | 25.096 | 25.361 | 25.625 25.899 | 26153 L 1 A. L | Liter to U.K. Gallon 1€= 0.21997 U.K, Gal —>—_ ° | 1 2 | 3 4 5 6 7 8 | 9 © 9220 0440) 0660| 0890) 1100) 1320| 1540] 1.760) 1980 10 2200 2420) 2640 | 2860/ 3.080| 3.300; 3520| 3.740 3.950 | 4.179 20 4399! 4619 4839! 5059| 5279/ 5499| 5.719] 5939) 6159) 6379 0 8799; 9019, 9.230| 9459 | 9679 | 9.609) 10.119| 10339) 10559. 10778 i pees) so | sasee! s1261 | 1146 | 1958 | 11576 | 12080 | 12318] 12sze| 12280 r2978 70 | 1398 15.618 15838 | 16058 | 16.278 | 16498/ 16718) 16938 | 17.158 17.78 80 17598 17.818 18.037 18.257 | 18477 | 18697 18.917 | 19.137 | 19.357 | 19.577 90 19.797 20.017 oar oa Late 20.897 ere ae tae tay 00-13CONVERSION TABLE kgm to ft.Ib 1 kg.m = 7.233 ft.tb TT 1 oO 1 | 2 | 3 4 5 6 7 8 | 9 2) ics) ess eos 10 723| 796 | 968 | 940| 1013) 1085 | 1157 | 1200 | 1902 | 1274 2 | ra7 | 1519| 1501 | 1654 | 1736 | 1808 | 1981 | r959 | 2025 | 2008 ao | avo | 242 | zs | 2007 | 20 | 2532 | 2604 | 2678 | 279 | 2821 40 2003 | 2966 | 3038 | 3110 | 3183 | 9255 | 3327 | 9400 | 3472 | 3584 i | | | | i 50 set | seo | 3761 | 9834 | 3906 | 3978 | 4051 | 4123 | 4195 4268 60. aaao | aan2 | gas | 4557 | 4629 | 4702 | 4774 | 4048 | 4018 | 4901 70 506.3 | 5135 | saos | soso | ssa seas | sea7 | S569 | soar | sina 80 578.6 | 585.9 | $93.1 | 6003 | 6076 | 6148 | 6220 | 629.3 , 6365 | 6437 20 510 | e582 | 6s ) 6727 | 6709 | 6071 | ome | 7018 | 7088 7101 100 7233 | 7305 | 7378 7450! 752.2 | 7595 | 766.7 | 7739 ' 781.2 | 7884 110 795.6 | 8029 | B10.1 | 8173: 8246) 831.8) 8390 | 846.3 | 8535 8607 120 | 8680 | 875.2) ag24 | 009.7 | 9069 | 9041 | or! 9186 | 9258 | 9231 130 9403 | 9475 | 9588 | 9620 | 9692 9765 | 9637 | 9909 | 9982 | 10054 140 10126 | 1019.9 | 1027.1 | 10342 | 1041.5 | 1048.8 | 10560 | roes2 | 0705 | 1077.27 H i ' i 180 10849 | 1092.2 | 10994 | 106.6 | 11199 | 1120.2 | 11283 | 11356 | 11428 | 11500 veo [sera jsnees wer ea | 962 /st924 2097 | zo 2151 |e 170] 11206 | 12368 | 12881 | 1251.3 | 12585 | 1265.8 | 12730 | 1260.1 | 12875 | 1298.7 reo | 13019 | 1309.2 | 13164 | 13236 | 13309 | sso 1345.3, | 19626 | 13898 | 13670 100 | 19743 | 1261.8 19887 | 19960 | 4022 | 14104 | 417.7 | va249 | want | a9 00-14 | |CONVERSION TABLE kg/cm? to Ib/in? 1 kg/em? = 14.2233 Ib/in? oli tejalels|elo]s Tar] me) ar 4 | 2} ava] 427] seo] ra) o63| 906 | 1138 | 1200 10 1422 | 1865 170.7 | 1849 | 199.1 | 2134 | 2276 | 2418 | 2560 | 270.2 40 5689 5832 | 5074 ons | con 640.1 | 6543 | 6685 | 6827 | 696.9 po | | 50 ria | 74 | 7396 | 7538 7681 | 729 | 7965 | 8107 | 8250 830.2 co | asae | asre | amie | e061 9103 ozs | 9087 | 9620 | 9672 ser 70 995.6 | 1010 pes [toss 1053 | 1067 | 081 | 1095 | 1109 124 we foe fase [ae net ae am fa a vo | 1200 | 1294 1300 192913971361 1368 | 1380 | 13841408 ee ee 110 [15651579 | 1502 16071621 1606-1650 6641678 1693 120 1707 wat 1735 1749 1764-11778 1792, | 1806 | 1821 | 1835. sso J rero a3 1677882 ene 1020 | 1938 89 | 18631977 ao | 1991 2008 2000 0a 204820622077 2081 2105218 150 [2194 2148 21622176 2190 20082219 asa 242082 eo [2276 2200 204 23182503347 2361237582388 2a0 vo | zee 2432 2446 © 24602475 | 24892503 2518 2532-2546 180 | 2560 2574 2589 2603 2617 2631 2616 | 2660 | 2674 (2688 190 |2702 27172731 2745-2789 2773«278B «280228162840 200 | 200s 0s 28732867 20012016 2030 zone | 2958 | 079 210 | 2987 | goo 018 3020 ao4s— | g058 ©3072 3085 3101 | a115 am jane aa asa ana nas mama mad mea | ner zo | sar | zg5 55003014 3528304357 a7 | 85 | 00 240 | 24nd 3428 ea 45634703485 B40 BHI 3527 saz | i L i el L _—__. 00-15CONVERSION TABLE ‘Temperature Fahrenheit-Centigrade Conversion. —A simple way to convert @ Fahrenheit temperture reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures, ‘These figures refer to the temperature in either Fahrenheit or Centigrade degrees, IH itis 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 itis 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. | 4 ve * |e * [- 404 | 40 | 400 W 18 78 “6 148 27.2 a 17.8 m2 | cas | “oe 2 | se] os | | use | me | 2 | oe dea | 30 | 720 | ssa | aa | ae | iise | mea | oo | vate a7 | 3 | 130 wa | sz | 94 | ao | rz02 | 200 | a | s0a2 mo | om | 00 ts | 90 | wo | so | tao | 204 | os | tes0 os | 419) 22 1s | os | re | s | 1238 | 200 | 6 | r058 ms | oa | eae | na | a | tase | 06 | or | tae a2 jin y ot we] eee [ote | oss faze | ott |e | ime Ter | Ne | a3 1 | cea | taz | se | tzoa | air | oo | to2 wile) so we | eo | ie | ss | iso | azz | 9 | mo se | os a» | oa | 193 | se | ase | oe | ot | vase 20 | 13 a6 2 | ne | 39 | 87 | 1306 | 333 2 | i976 zea 2 | 104 2 | ma | ua | se | rea | a9 | os | 1094 -n9 | -1 | 12 2 | 752 | 150 | so | se2 | ase | oe | zone m3 | o | wo xm | m0 | ise | eo | woo | a0 | os | amo ry -ne |! -9 | 158 26 7188 161 or 1418 356 6 204.8 za | a | ie » | ws | wr | er | wos | oss | ov | ame ma | | tea ze | aa] m2 | os | vse | 367 | 90 | mea my) 6 oN 2 42 178 64 147.2 m2 9 210.2 ws! s | ao | 1 | 30 | aso | ws | os | too | ara | wm | a0 zoo | «| ms | -o6 | » | ars | wo | 66 | wos | woe | 10s | 2210 194 | 3 266 o 32 | 898 194 67 1826 433 110 230.0 wo | 7 | ma | os 3 | sa | m0 | 62 | ise | asx | is | 2000 wea | 1 | woz | ora | ae | az | zw | oo | te | ae | to ve | 0 | 220 17) 38 | 950 | ar | 70 | 1580 | 517 | 125 | 2570 | 1 338 22 36 68 27 ” 159.8 se 130 266.0 2 | ae] za | a | oe | zz | a | wre | oz | tos | 260 a | are | a3 | as | me | za | 23 | tere | ooo | two | soto «| a2 | as | ae | soar | aaa | me | teez | err | as | a000 sia | aa | a | sooo | za | os | sero | ose | io | sono uaa | | as | so | a | rose | 20a | sas | uss | ano Tao | 7 | as | se | 2 | tore | aso | oe | na | wo | smo Tas | a | aa | as | a | toa | ee | oe aa | es | amo cee | 9 | az | er} fone | we |e re | am | anno “a2 | wo | woo] oz | as | uso | mr | ma | us | aero 00-1601 GENERAL General assembly drawing soon Oe 2 Specifications... Weight table : List of lubricant and water... PC75UU-2 01-1GENERAL GENERAL ASSEMBLY DRAWING GENERAL ASSEMBLY DRAWING Ti CAB SPECIFICATION at aes i fn Unit: mm Serial No. 5001-10370 = Figures in ( ) steel shoe specification PC7SUU-2GENERAL ASSEMBLY DRAWING Serial No. 10371 and up Unit: mm. suv01s62 Figures in ( ) steel shoe specification PC7SUU-2 01-3GENERAL: GENERAL ASSEMBLY DRAWING ros CANOPY SPECIFICATIONS) Serial No. 5001 - 10370 “ Unit: mm ‘* Figures in ( ) steel shoe specification 01-4 PC7SUU-2GENERAL GENERAL ASSEMBLY DRAWING Serial No. 10371 and up Tt a Unit: mm stpo13e3 suvorse2 ‘* Figures in ( ) steel shoe specification PC7SUU-2 01-5 @GENERAL ‘SPECIFICATIONS SPECIFICATIONS Machine model PC7SUU-2 Serial Number 5001 - 10370 Specifications Cab specification | Canopy specification Cab specification kg 7,75017,850) 7,60017,700} Bucket capacity m 0.28 0.28 Max. digging depth mm 4,200 4,200 Max. vertical wall depth mm 3,040 3,040 | Max. digging reach mm 6,360 6,360 B | Max. reach at ground level mm 6,290 6,290 3 | Max digging height mm 7,160 7,160 = | Max. dumping height mm 5,050 5,050 =| g | © | Bucket offset (lofuright) mm 1,075/1,020 1,075/1,020 5 Max. blade lifting height mm a5 a5 3 Max. blade lowering depth mm 210 210 “| Max. digging force KN (kg) 48.1 (4,900) 48.1 (4,900) ‘Swing speed | pm 8s a5 ‘Max. slope angle for swing | deg. 13 3 Travel speed | km 38 38 Gradeability | deg. 35 35 Ground pressure la eee kPa tkglem’) 34.3 (0.35) 34.3 0.35) Overall length (for transport) mm 6,030 6,030 Overall width mm 2,320 2,320 Overall height (for transport) | mm 2.700 2,685 Overall height | mm 2,700 2,685 Ground clearance of counterweight | mm 817 817 | Min. ground clearance mm 360 360 ® | Toil swing radius mom 41.180 1.150 E | Min. swing radius of work equipment | mm 1,150 1,150 é Height of work equipment at min. mm swing radius, ea) a Length of track on ground mm 2,220(2,205) 2,220)2,205} Track gauge mm 1,870 1,870 Overall length of track mm 2,86512,835] 2,652,835} Blade width x height mm 2,320%470 2,320x470 Figures in| |: Steel shoe specification 01-6 PC7SUU-2 @motor ‘Swing motor GENERAL SPECIFICATIONS, Machine model PC7SUU-2 Serial Number 5001 - 10370 Specifications Cab specification | Canopy specification Model 4095L-1 409511 4-cycle, water-cooled, | 4-cycle, water-cooled, Type vertical, direct injection |vertical, direct injection No. of cylinders - bore x stroke mm 4-95 «118, 4-95 115 | Piston displacement eco 3.260(3,260) 3.260(3,260) Firing order 1-2-4-3 1-2-4-3 «| Fivwheel horsepower | kW (HPyrom| 40 {54.2)/1,900 40 (64.21/1,900 £ | Mex. torque ‘um (gm) rpm] ——-228428)1,500 225(29)1,500 S | Max. speed at no load tpm 2,100 2,100 Min. speed at no load rpm 900 900 Min. fuel consumption lanwn (onPro] 218 (162) 218.(162) Starting motor 24V, 2.8kW 24aV, 2.8KW Alternator 24V, 158 24V, 15A Battery | 12V, 65Ah x2 12V, 65Ah x2 Radiator core type | cps cos Carrier roller | Ton each side Track roller 5 oneach side Track shoe Road liner (39 each side) a | Type xno. Tandem piston type + Gear type x 1 § | Discharge | amin 78x2+48,11 & | Set pressure for work equip: spa txgiem’ ete | Ben ewing avel MPa tkg/em’}| 24.5 {250} (Bucket dump: 22.5 (230}) 3 * Offset, blade [MPa {kg/cm} 20.5 210) a * Control |MPa {kg/cm} 2.9 {30} eS 2 (8 4] type xno. 4-spool x 1, 3-spool x 2 3 83} Control method Hydraulically assisted + travel and blade 812 | save . Piston type (with reduction gear, counter- = Is ones H balance valve, parking brake) x 2 = Piston type (with brake valve, parking brake) x 1 | Hydraulic eylinder i | Hydraulic tank | Hydraulic filter Double-acting piston Box-shaped, open Tank return side cooled [ Hvarauie cooler ‘ Figures in ( ) steel shoe specification PC7SUU-2GENERAL ‘SPECIFICATIONS Machine model PC7SUU-2 10371 and up Cab specification | Canopy specification Cab specification 'g 7,65017,750] 7,50017,600] Bucket capacity mm 0.28 | 0.28 Max. digging depth mm 4,200 4,200 Max. vertical wall depth mm 3,040 | 3,040 @ | Max. digging reach mm 6,360 6360 2 | Max. reach at ground level mm 6,290 6,290 @ | Max. digging height mm 7,160 | 7,160 & | Max. dumping height mm 5,050 5,050 g | © | Bucket offset (lefvright) mm 1,075/1,020 1,075/1,020 = Max. blade lifting height mm a5 415 3 Max. blade lowering depth mm 210 210 Max. digging force KN tka) 48.1 (4,900) 48.1 (4,900) ‘Swing speed rom as 85 Max. slope angle for swing | deg. 13 13 Low: 3.5/High: 4.2 Low: 3 5/High: 4.2 Travel speed kev (Low: 3.2tHigh: 3.9) | (Low: 3.2migh: 3.9) Gradeability | deg. 35 35 coe KPa tkgiems] 34.3 (0.35) 343 (0.35) Overall length (for transport) mm 6,030 6,030 Overall width mm 2,320 2,320 Overall height (for transport) mm 2,700 2,685 Overall height mm 2,700 2,685 Ground clearance of counterweight | __ mm. 817 817 @ | Min. ground clearance mm 360 360 3 | Teil swing radius mm 1,160 1,150 —| ‘swing radius of work equipment mm 1,150 1,150 a Height of work equipment at min. } swing radius mm oe oa Length of track on ground mm 2,22012,205} 2,202,205} | Track gauge mm 1,870 1,870 | | Overall tength of track mm 2,86512,835] 2,86512,835] Blade width x height mm 2,320x470 2.320470 Figures in| ]: Steel shoe specification 01-8 o PC7SUU-2GENERAL SPECIFICATIONS: Machine model PC7SUU-2 Serial Number 10371 and up Specifications Cab specification | Canopy specification Model | 409514 4p96t-41 | 4-cycle, water-cooled, | 4-cycle, water-cooled, Type vertical, direct injection |vertical, direct injection No. of eylinders - bore x stroke mm 4-98 «115 4-95 115 Piston displacement tee} 3.26043 260} 3.26013,260) Fring oer toeeen | teaeacs «| Fivwhee! horsepower |KWA(HPYicpm} 40 (54.2¥/1,900, | 40 (54.29/1,900 © Max. torque ‘nm kgm om] 225125)1,500 225423)1,500 © | Max. speed at no load | pm 2,100 2,100 Min. speed at no load tom 900 | 900 Min. fuel consumption lonwn cent 218 (162) 218 (162) Starting motor 24V, 2.8kW 2av, 2.8KW Alternator rasa | av, 15 Battery 12V,65Anx2 | 12, 65Ahx2 Radiator core type D3 D3 «@ | Cartier rotler on each side BE) track roller | 5 on each side 38 | track shoe { Road liner (39 each side) | | Type xno, Tandem piston type + Gear type x 1 Discharge tin 78x2+44,11 |S | Setpressure for work eauio- Inipe ier] 24.5 (250) (Bucket dump: 22.5 (2300) + Offset, blade MPa kg/cm 20.5 210} * Control MPa tkofem} 2.9 (20) Type x no, Control method | 4-spool x 1, 3-spool x 2 Hydraulically assisted + travel and blade 3 | Travel motor Ea motor ‘Swing motor Piston type (with reduction gear, counter- balance valve, parking brake) x 2 Piston type (with brake valve, parking brake) x 1 Hydraulic cylinder Hydraulic tank Hydraulic filter | Hydraulic cooler Double-acting piston Box-shaped, open Tank return side Air cooled ‘* Figures in ( ) steel shoe specification PC7SUU-2GENERAL WEIGHT TABLE WEIGHT TABLE Ay This weight table is a guide for use when transporting or handling component. u nit: kg Machine mode! Pc7suU-2 Serial Number 5001 - 10370 10371 and up Engine, hydraulic pump assembly 425 425 * Engine (with mount) 340 340 +PTO 20 20 * Piston pump + gear pump 63 63 Radiator, oil cooler assembly a a Fuel tank (without fuel) 82 82 Hydraulic tank (without oil) 60 60 Canopy 59 59 Operator's cab 172 172 Revolving frame (without counterweight) 1,980 | 1,980 Counterweight 1,040 1,040 ‘Swing circle m mM ‘Swing machinery 52 52 Track frame assembly (with piping, cover) 2,36012,450] 2,36012,450] * Track frame 865 865 * Idler 52x2 52x2 * Recoil spring assembly 43x2 43%2 + Track roller 21x10 13x10 * Carrier roller 22x218x2] 4x2 * Sprocket 23%2 23x2 Track shoe assembly ‘+ Rubber shoe (450 mm) (435 x 2] (435 x2] * Steel shoe (450 mm) 447 x2 487 x2 + Road liner (450 mm) 390 x2 376x2 Figures in { |: Steel shoe specification 01-10 PC7SUU-2GENERAL WEIGHT TABLE Unit : kg Machine model PC7SUU-2 Serial Numbe 5001 - 10370 10371 and up 3-spool control valve "7 7 3-spool control valve v7 | ” 4-spool control valve a " " Swing motor a 2 Center swivel joint 26 26 Travel motor 902 0x2 Boom assembly | += 1st boom 328. 299 * 2nd boom 229 1 189 # ard bracket 184 126 * Sub tank 5 25 ‘Arm assembly 163 186 Link assembly 55 58 Bracket assembly 210 210 Blade assembly 314 j 314 Boom cylinder assembly 108 108 ‘Arm cylinder assembly 90 30 Bucket cylinder assembly 47 47 Offset cylinder assembly 47 47 Blade cylinder assembly 48 48 PC7SUU-2 01-11 oGENERAL LIST OF LUBRICANT AND WATER LIST OF LUBRICANT AND WATER RESERV KIND OF AMBIENT TEMPERATURE CAPACITY (2) -SERVOIR 2-4 16 32 50 6886 108 122% Fup 30 2010 0 020 50_&o._“Zore| Specified | Refill | ‘SAE 3 | ~ SAE 10W j | Engine ol pan t 20 1 ° THRE ‘SE inwad, y PTO case | 09 os OH engine oi I ‘Swing machinery case Ey 18 16 Final drive as | 7 w Idler (each) l I 0.06 - ———_ ee “rack roller (each) 009 - Carter rover each) | reese ALBANIA EBS anasto | = aE 10 | —— — Hydrauic system | Engine oi aT mile CSS (a Fel tank Diese fuel - ASTM D975 No.2 00 tt T Cooling system [Coolant | Ade antreeze 9 - ‘* Figures in | ] : Stee! shoe specification 01-12 PC7SUU-2 ®GENERAL NOTE: ‘+ When fuel sulphur content is less than 0.5 %, change oil in the oil pan every periodic main- tenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5 %. Fuel sulphur content | Shange interval of oil in engine oil pan 0.5 to 1.0% 1/2 of regular interval ‘Above 1.0 % V4 of regular interval ‘+ When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAE1OW, SAE10W-30 and ‘SAE15W-40, even though an atmospheric tem- perature goes up to 10°C more or less in the day time. ‘© Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. ‘+ There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but, be sure to add single grade oil that matches the temperature in the table on the left. * We recommend Komatsu genuine oil which thas been specifically formulated and approved for use in engine and hydraulic work equi ment applications. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspec- tion and maintenance. PC7SuU-2 LIST OF LUBRICANT AND WATER 01-13 @o21wo2 10 STRUCTURE AND FUNCTION Hydraulic piping diagram 10-2 Hydraulic circuit diagram Electric wiring diagram.. So 104 Electric circuit diagram 106 10-1HYDRAULIC PIPING DIAGRAM zomizo i 10 24, Offset PPC valve 25. Blade cylinder _21WF 02009 a 10-2oz1wo2 HYDRAULIC CIRCUIT DIAGRAM Hydrate tank FIN 10 85 Fee engine ‘oss Shaina pump Seerev ‘Arm eying doses Binge cylinder Offered. Stopes zrwr02010 10-3ELECTRIC WIRING DIAGRAM Cancel switch Horn switch ‘Attachment selection connector Monitor panel Starting switch ‘Swing brake cancel switch Fuse box Cancel resistance ‘4-system controller Sexe aenn 10-4 oz1woz wr 02036 10. Wiper switch (cab specification) 11, Heater switch (cab specification) 12. Lamp switch 13. PPC lock switch 14, Heater (cab specification) 16. Alarm buzzer 16. Glow signal (resistor) 17. Stop motor relay 18. Swing brake timer ‘‘oz1wo2 6 a a rr) 0 31 19. Arm potentiometer 20. Battery 21. Fusible link 22, Battery fluid level sensor 23, Battery relay 24. Right swing oil pressure switch 25. Offset potentiometer 26. Left swing oil pressure switch 27. Working 28. Boom poter 30. Wiper motor (cab specification) 31. Engine stop motor 32. Room lamp (cab specification) 33. Engine oil pressure sensor 34, Radio (cab specification) 36. Starting motor ‘36. Coolant temperature sensor 37. Alternator 38. Fuel pump 39. Fuel level sensor 40. Swing brake solenoid valve 41. PPC lock solenoid valve 42, Boom RAISE stop EPC valve 43, Arm IN oil pressure switch 44, Arm IN stop EPC valve 45. Boom LOWER stop solenoid valve 46. Left offset stop solenoid valve 47. Horn iwrozas7ELECTRIC CIRCUIT DIAGRAM Serial No.: 5001 — 5494 erty Radio {e2b specication) to, o mae Rape Sab. a Fuel Level system contolor i i bi o21wo2o21wo2 Serial No.: 5495 and up Wir ewiten Regio Fuse bx connection ala [Sb Speciation! {cab pecticatn) A Werk, Un na ‘Sit bee ar isl [a[ [5 00m, ni Baten. “wen iow potenti TPT TS [neces [= 0] E Ojesrasst a hs eeroro [eo] = a vate Se a: [f= BS er © oom larg | [cab specication) _ Se HOS | acre 10-7o21wo2 20 TESTING AND ADJUSTING Table of judgement standard value Standard value table for electrical parts Tools for testing, adjusting, and ‘troubleshooting .. ‘Measuring engine speed ‘Measuring engine oil pressure Measuring compression pressure . Measuring blow-by Adjusting vaive clearance Testing and adjusting fuel injection timing Testing and adjusting alternator fan belt tension Adjusting fuel control lever ... Testing and adjusting track shoe tension Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit. Testing conrol circuit pressure... Measuring output pressure of PPC valve Adjusting PPC valve Measuring outlet port pressure of solenoid vaive, EPC valve Measuring oil leakage inside cylinder ‘Measuring oil leakage from swing, travel motor. . Bleeding air from hydraulic circuit. Releasing remaining from hydraulic circuit . Adjusting blade control lever . ‘Adjusting travel contro! lever Procedure for resetting electrical system inpuvoutput signals and checking operation sens 20-40 Procedure for replacing potentiometer... 20-52 Procedure for checking diode... 20-63 Trobleshooting 20-55 + Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting, 1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. 2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of opera: tion to judge if there is a failure. 3. These standard values are not the standards used in dealing with claims. When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use blocks to prevent the machine from moving. AA Wren carrying out work together with other workers, always use signals and do not let unauthorized people near the machine BA Winn checking the water level, always wat forthe water to cool down. Ifthe radiator cap is removed when the water i stil hot. the water will spurt out and cause burns. By be caret not 0 get coughtin the fan, fon belo other rotating pars 20-1TABLE OF JUDGEMENT STANDARD VALUE + FOR ENGINE ‘Applicable model Engine hem Measurement T Unie Service imit value | | High idting ‘pm 2,100 50 - Engine speed | Low idling om 1,000°§° - Rated speed om 4,900 - ‘At sudden scceleration | Bosch Max. 5.0 Exhaust gas color Athigh idling tered Max. 2.0 Max.3.0 Intake valve mm 0.36 - Valve clearance {normal temperature) | evnouet valve mom wo _ Oil temperature: MPa Min. 29 Compression pressure 40—60°C |kgiem’} (Min. 30) (SAESO oi engine speed) (com) (320-360) Blowby pressure (Water tempera Max. 50 Max. 100 ‘Operating range) |mme,o| rence value) rence valu {SAE30 oil) paraneete 40] (Refer ue) (Refe ue) (Water tempera Operating range) 1 034-066 Min. 0.25 ioe nar one oo) (35-65) (Min. 2:5) Oil pressure SAE 10W | MPa Min.021 Iegiem] (Min. 2.1) Atlow idling SAE 30 SAE 10W Oil temperature baited ae c 80-110 Max. 120 Fuetinjcton timing | Baoretop ded contr | weet - Deflection when Fan belt tension pressed with finger | mm 6-10 - force of approx. 9. 20-2 o21wo2o21woz + FOR CHASSIS Applicable model Pe7suu-2 cae [Standard vaive for] Service limit Ca tem Measurement conditions unit Standard value vice ~ Hydraulic oll temperature: 45 65°C B | at t-pump reliet + Engine oil pressure: Min, 1900 Min, 1,900 : ‘Within operating range H + Engine water temperature rpm z Within operating range 2) azpumpretet | « 1-pump relict Bucket rele! Min. 1,900 Min. 1.900, { 2:pump relief Bucket «arm raat t[*]e|?le|e Boom control valve ol 7 [7 fej7 | > Ld Boom boost contol valve aleleja|es |e | arm control valve | a j7)7}ej7|7 J | Bucket control valve | a bali nT 2 | Offset control valve | & alel|eiale|6 ‘Swing control valve creme Blade control valve ——, w|s|s miss t 1 | Let travel control valve n_| | =a ws|6 | 6 |res| 6 | 6 Right rave control valve f Nowa syaeayg | | oom controler | * CAE oflever RAISE, LOWER so29 30:18 + Tip of pedal Arm controttever | 7 RESAPOM cURL, DUMP s0x8 sorte to4end of travel Bucket controllever | « Engine stopped _N-» CURL, OUMP sor8 so218 $ | swing control ever N+ LEFT, RIGHT sor9 sete 8 | Offset control pedal (N-— LEFT, RIGHT 2142 ata & | mm B| pindecontotiever | N+ RAISE, LOWER wis | aset0 8 | > FORWARD, | Travel contol ever fevense 95410 95420 i ‘Work equipment | 3-5 8 Play of control lever contollever=™ | | 38 | 88 Travel lever | 3073 «|e Fuel contol lever Low + High 185+ 20 185 +20 20-3‘Applicable mode! Pc7suU-2 ca] — it [Standard value for] Service fi oe tem Measurement condi Unit [Standard value vice tk + Engine at full throttle 176249 Max. 245 trol lever A i Eee + Oil temperature: 45—55°C Ge) eee rm control lever | * Fit push-pull scale to center of control 157249 Max. 225 ‘Arm control lever knob to measure ieee (Max. 2.3) g ++ Fit push-pull scale to tip of pedal to 157249 Max. 22.5 | Bucket controltever | * rmeseure (8205) (Mex. 23) 3 ‘+ Measure max. value to end of travel 76249 Max 245 | Swing control tever nw |__aazos) (Mex. 2.5) S 09) |7aazas Max. 117.6 g | Offset contro! lever (0205) (Max. 12) 2 26.4449 Max. 33.3 B | Blade contro ever 7205) (Max. 34) 5 25 Max. 28.4 & | travel control tever (22408) (Max. 28) 343 343 Low — High (3540.5) (3.5 + 0.5) Fuel contro! lever “ae - 191 High + Low (2,040.5) (2.0 + 0.5) Boom 235°37 (240°3) | 23.5703 (2407'2) + Oil temperature: 45—55°C +07 (950°? "3819502" rm 245°87 (250%) | 248!3812502"9) A + Relief pressure with engine at full 0% throttle 245°7 250°) | 245°32 aso" Bucket {Relieve only circuit to be measured) 37 250°3) | 24.5738 (2502'S) Offset 20.657 (210°3) | 20.6738 (210""2) $| swis 20.6737 (210°9) | 20.6 °98(2107"5| §| Swing we 238(210"%) 3 f 5! plage 206°? 210°%) | 20.6788 1210°"2) 3 | Travel 245°9? (250°9) | 24.5738 1250") zs Charging pump | a0stargy | 30°91) | Drop in hydraulic pressure + Hydraulic oil temperature: 45—55°C + Difference in relief pressure with engine at 1/2 of rated engine speed {and relief pressure with engine at full 8 pump (Max. 30) Max.2.9 (Max. 30) 20-4 oz1wo2oz1wo2 Applicable model PC7sUU-2 tem ‘Measurement conditions Unit ‘Standard value for] Rew machine. ‘Service limit value ‘Swing Overrun when stopping swing Work equipment posture yy, em wuF02274 ‘+ Engine at full throttle + Hydraulic oll temperature: 45—5°C + Stop after swinging one turn and mee sure distance that swing circle moves. (O: Distance of movement on outside circumference of swing circle Max. 35 (Max. 260) Max. 40 (Max. 300) Time taken to start swing | 45—55°C | « Time taken to swing 90° and 180" Work equipment posture 44, €—S, 23203 (28203) Max.2.9 (Max. 3.4) ery 72ouFO2274 ‘+ Engine at full throttle | + Hydraulic oil temperature: 180" from starting position Max. 4.7 (Max. 5.3) 41203 (46203) | Time taken to swing Work equipment posture Max reeeh em 2ouro2274 | + Engine at ful throttle «+ Hydraulic oil temperature: 45—55°C ‘+ Swing one turn, and measure time taken to swing next 5 turns 3542 Max. 40 Hydraulic drift of swing Work equipment posture: Max. reach, bucket at rated load or fully loaded with soit | Rated toad: 450 kg) z zouro227s {"™ Engine af full throttle Hydraulic oil temperature: 45—85°C | ‘Set machine on 15° slope, and set Upper structure at 45° to the front. ‘+ Make match marks on swing circle ‘outer race and track frame. ‘+ Measure distance that match marks ) 0) move apart after 15 minutes. LApplicable model PC7SUU-2 cao] tem ‘Measurement conditions Unit [Standard value for] _ Service limit Rew machine value Leakage from swing motor ‘Swing + Relieve swing circ Engine at full throttle Hydraulic oil temperature: 45—55°C _ |4y mig Max. 1.5 Max.25 ‘Travel speed (1) Posture for measurement + Engine at full throttle + Hydraulic oll temperature: 45—B5°C + Raise track on one side at atime, rotate FR 20UF02276 ‘one turn, then measure time taken for next 5 turns. 3443 ‘Travel speed (2) Travel Posture for measurement + Engine at full throttle + Hydraulic oil temperature: 45—56°C + Run up for at least 10m, and measure 2ouF02277 time taken to travel next 20 m on flat ‘ground. : Rubber shoe specification machine 2342 (2142) (25) Travel deviation Posture for measurement + Engine at high idling + Hydraulic oil temperatur + Run up for at least 10 m, and measure | ™ ‘4 Use a hard horizontal surface. + Measure dimension x a 45—55°C deviation when traveling next 20 m on flat ground. ‘Max. 200 20 Leakage of i from | + Hydraulic oil temperature: 45—55°C twit chp" AB Apply relief pressure to porttobe — bemin Max. 10 Max. 50 20-6 o21wo2o21wo2 Applicable model PC7SUU-2 (each cylinder) ome =m -cauramentcondiona na | Standard valve for] Service mit ‘gory S - " conditi Unit | Phew machine value | Posture for measurement Hydrate dit of travel aouroera\™ ° ° 3 + Engine stopped : 1 Hydraulic oll temperature: 45 55°C & + Stop machine on 12 slope with sprocket facing straight up the slope. + Measure the distance the machine moves in 5 minutes. + Engine at fl throwle Leakage of ravelmator | * Hydraulic olteomperature: 45~55°C |tnin] — pagy ‘+ Lock shoes and relieve travel circuit. ee Ca) 1 Posture for measurement Total work equip- || ment i Uhydrautc ait ot Max. 540 Max. 810 ‘ip of bucket eet) | i || s00m onder | | | |_| tamountofretract un | | | fon of evinderd | 20uF02279) Max. 41 : | + Pacoin above posure and mesure | s ‘extension or retraction of each cylinder z | and downward movement at tipof | = | bucket teeth. | | |B | Amovtindor | + Horizontal fat ground | § | E | tamount of estens} + Bucket Rated load (450 ko) mm | Max.32 | Max. 8 2/3 ion otoyinder | + Levers at neutral | Se | +E ‘stopped 1 | 3/3 | 5 Hiydaule ol temperature: 555°C | 8)-2 || i Stiermeesucing immediately attr | He setting. 3/3 | euckercyinder | * Measure hydeaulic dit every 5 Fi minutes and judge from rests fr 15 Max.11 Max.17 [on of vinden | | + Engine stopped | | Blode | Hydraulic ol temperature: 45—55°C | || downward | * Raise blade to max. height, then mea Moc20 | Max 00 | trovementattip | sure downward movement at ip of | | oriadey [bases ate | | + Hydraulic oil temperature: 45—55°C | | Leakage from cylinder | * ABP rele pressureto cinder be lamin] Max a5 | Max. 75 |‘Applicable model Po7suu2 ean] wom Meszurement conditions [uni |Standard vale for] Service tie son row machine Foatre Tor measurement 00m 4 Becket eth in con: 4 aeio4 Max. 48 tect wth ground z ematy Cylinder fully. & extended zourezzs0| & 204 Max.5.0 + Engine at fll tote g + Hydraulic ol tmperatur: 45 55°C Posture for measurement arm zi Cylinder fully 5 4404 Max.5.3 ferrected 3 SS Emsty 5 Fully extended | pourazze: | 2 3.4103 Max. 4.1 ‘+ Engine at full throttle o { Hydroute o temperature: 45—55°C | Posture or measurement | Bucket z Cylinder fully. gs 3.50.4 ‘Max. 4.2 §| £| rotacea 3 5) see. fe Emery 2 $| 2) ruty enendea couramee| 22:03 Max. 20 5 3 #\3 + Engine at full throttle 2 + Hydraulic oil temperature: 45—55°C) Posture for measurement : 5 4905 Max. 59 | § \ ‘20UF02283 : 3940.4 Max. 4.7 + Engine at fll throtte & + Hydraulic oil temperature: 45—55°C, © Posture tor measurement 3 1.0103 Max.18 § Blade ful raised aourozzes| 13t03 Max.21 + Engine at full throttle oy lic oll temperature: 45—55°C| 20-8 o21wozo21wo2 Applicable model PC7SUU-2 cae] gor tem Measurement conditions Unit ‘Standard value for] Service limit value Work equipment Time lag Boom Posture for measurement } Ce + Engine at low idling 20UF02285 + Hydraulic oll temperature: 45—55°C + Retract arm, boom cylinders fully and set boom at max. height. Lower boom and measure time taken from point where bucket contacts ground to point where chassis rises from ground Max. 2 Max. 2 Posture for measurement "0uF02286 + Engine at low idling «+ Hydraulic oil temperature: 45—55°C + Set top of boom horizontal and retract, bucket cylinder fully. Then extend cy!- inder and measure time taken for arm_| {0 stop at bottom and then start again | Bucket Blade Posture for measurement ‘20uF02267 + Engine at low idling + Hydraulic oll temperature: 45—55°C + Set top of boom horizontal and retract ‘arm cylinder fully. Then extend cylin- {der and measure time taken for bucket {0 stop at bottom and then start again | Posture for measurement a, ‘20uF02268 low idling + Hydraulic oil temperature: 45—55°C + Raise blade to max. height. Then lower boom and measure time taken from point where blade contacts ground to point where chassis rises from ground 20-9STANDARD VALUE TABLE FOR ELECTRICAL PARTS nape sys] Connector Measurement Name of component tion Judgment table tem ia No. [22h | conditions Ifthe condition is as shown in the table 1) Turn staring bo 2g | below, is normal switch ON. wer source 32 2) Insert T-adapter. voltage a % | [Between @), (17), — , ss > (18) and chassis 7 If the condition is as shown in the table 1) Turn starting 2g | below, itis normal switch ON, Model selection! = K2 ge 2) Insert T-adapter. 85 || Berweente,, | - 2? (8) and chassis. OO ye condition is as m in the table 1) Turn starting wn jp [Sumtmareerree |e ork equipm- 32 a rw . entsolecion | | 33 | [ worweon tsi,16. | 39 ayy || 2 Insert Tadonte 25 | | 17,118) and chassis - Ifthe condition is as shown in the table 1) Turn staring below, itis normal switch ON, 2) insert T-adapter. A When resett- | Between (11) 9 _ ay $3 | | ing Resetsignal | x2 | 28 | | sion Between (12)} go — eset sig a2 || 5 twee 20 —30v i = Whan reser | Betsen "| 20 — aov Ing output & Signal Between (12) . ae — chassis o-w Ifthe condition is as shown in the table 1) Turn starting . 2 g, | below, itis normal switeh ON. 300m meter | K # Between K210)—(@ [48 SAV—]| 2) Insert T-adapter. | Teorween K31@-—KaIe) | 0580860 —]| 3) End of boom a RAISE stroke. Ifthe condition is as shown in the table 1) Tur starting a Se is normal switeh ON, potentiometer | 2 | $2 | [ Bemeen ene) Sesvmm| [set tenons Between K3IN)—K29)| 046 — 1.28 End of I the condition is 0s shown in the table Ty Turn staring oftet ge switeh ON, none | 9 | EE |[aemaeste ar [—aaTaTy | heart © | laeweon R310) = 3) End of right K3(10)—Katsi] 320-432 End of right T the condition is as shown in the table 7) Tum starting ee gg | below, itis normal switch ON. | stop solenoid | Ka & | [When aavated | potweon (7, |_20~30V_]| 2) Insert T-adapter. eer > | [Wien otaauned] (8) ~ chassis [ “9 —3v 20-10 o21wo2o21wo2z inspec 3a] Connector | age ‘Measurement 225) Name of component | Ome" [on Judgment table conditions Tithe condition is as chown inthe table | 1) Turn staring $ 8 | below itis normal pwitch ON Lettotset stop | Kt 2) Insert adopter. solenoid valve £4 | [Whenscuatod | petwoen 10,,| 20—30v ]| | Wher aed |(17)— chassis 9 — 3 ifthe condition sas shown inthe table | 1) Turn stating g | below, ts normal Switch OFF Boom potertiome- | M11 & | [Between (t)— 2) 02 — 7a 2) Disconnect con- ter (female) é Between (2) — (3) 0.2 —7kO Between 1) — (a) | 4—6k0 Tithe condition sas shown inthe table | 1) Turn starting | below, iti normal witch OFF | 2) Disconnect con- eee ar | [aeweent a [02 70 ee | ter | matey | [Between 2)— cay | 02-70 | Between (t)—(@) | 4 — 60 ifthe condition sas shown inthe table 1) Turnstaning | eg tomtisnorma pwitch OFF | Qfserpotaniome: | Mis, g 8 | Berweeniti—@ | o2—7a | permet eon: am | mle) 2 | Between 2) @) | 02-70 i | comin el =e - | ~ if the condition is as shown in the table 1) Turn starting 8, below: tis nerme! switch OFF Boom RASE stop Katinae) 5 | [ petween K20—K19 | 8— 280 | 2) Disconnect con Erevalve Kiatemale | 3 2 1? Sector. 22 || etween «20, x19 in j E || Benassi ee ||| i [ifthe condition is as shown in the table 1a) Turn starting 2 § | below is normal Switch OFF Arm N top PC 2 [someon xis-xig | 6= 360], 2 Osconnect con 28 | aemeentg5 18 | yin wo ifthe condition is as shown in the table | 1) Tum starting ' 8 below, itis normal switch OFF Boom LOWER stop xSOImale) 28 [BerwoankS0-KS1_| 55 —e00 | 2! Disconnect con- EPC valve K6tfemale) | 8 2 | | nector. 38 ||” Between x50, KS1 naan (LE : j ifthe condition is a8 shown in the table | 4) Tum starting 9 8 below, tis normal i” Dates OFF Left offset stop Ks2(male) 2 5 | oon KGZ—KES seo 2) Disconnect con- EPC valve Ks3omalo) $3 | a ee | rector. B | | Berypen ts Min. 1Mo 20-11