PC750-6 Sebm025303 PDF

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

1
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
‡ 00- 3 01- 5 10-16 10-46 10-76
‡ 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
‡ 00-15 10-29 10-58 10-88
‡ 00-16 10-30 10-59 10-89
‡ 00-17 10- 1 10-31 10-60 10-90
‡ 00-18 10- 2 10-32 10-62 10-91
‡ 00-19 10- 3 10-33 10-63 10-92
‡ 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
PC750, 800-6 00-2-1

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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
00-2-2 PC750, 800-6

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20-151 20-264 20-401 20-442 20-564

20-152 20-265 20-402 20-443 20-565
20-153 20-266 20-404 20-444 20-566
20-154 20-267 20-405 20-445 20-567
20-155 20-268 20-406 20-446 20-568
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
20-163 20-276 20-414 20-503 20-576
20-164 20-277 20-415 20-504 20-577
20-165 20-278 20-416 20-505 20-578
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
20-290 20-428 20-609
20-251 20-291 20-429 20-551 20-610
20-252 20-292 20-430 20-552 20-611
20-253 20-293 20-431 20-553 20-612
20-254 20-294 20-432 20-554 20-613
20-255 20-295 20-433 20-555 20-614
20-256 20-296 20-434 20-556 20-615
20-257 20-297 20-435 20-557 20-616
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
PC750, 800-6 00-2-3

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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)
20-631 30-26 (1) 30-66 (1) 30-107 (1) 30-147 (1)
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
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.
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.

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.

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
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.
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.
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
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
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
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
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
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)
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

LOADING SHOVEL SPECIFICATION

DIMENSIONS
WORKING RANGES
01-3-1 PC750, 800-6

(3)
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
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
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)

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

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

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

Machine model PC750LC-6

Model SAA6D140E-3

Performance

Engine

Alternator 24V, 50A
Hydraulic
carriage
Under-

pump

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

valve

Hydraulic
x 2 (MSF-340VP)
motor

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
PC750, 800-6 01-7



Working ranges
Max. vertical wall depth mm 5,230 4,080


Performance



Overall width mm 4,325 4,325


Dimensions



01-8 PC750, 800-6


Model SAA6D140E-3
Performance
Engine

Alternator 24V, 50A
carriage
Under-

Hydraulic
pump

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

valve

Hydraulic
motor
x 2 (MSF-340VP)
Hydraulic system
x 2 (KMF125AB-5)
Bucket
Boom Arm
PC800-6 PC800SE-6
Hydraulic cylinder

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
PC750, 800-6 01-9

LOADING SHOVEL SPECIFICATION

PC750-6
Machine model


Working ranges
Max. vertical wall depth mm — —


Performance



Overall width mm — —

Dimensions


01-9-1 PC750, 800-6

(3)
PC750-6
Machine model
Model SAA6D140E-3
Performance
Engine

Alternator 24V, 50A
carriage
Under-

Hydraulic

pump

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

valve

Hydraulic
x 2 (MSF-340VP)
motor
Hydraulic system

x 2 (KMF125AB-5)
Boom Arm Bucket Bottom dump

Hydraulic cylinder

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
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

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

Unit: kg
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

Unit: kg
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)
15. Drain plug
Specification
Reduction ratio:
20 + 97 19 + 97
x = 35.716
20 19
Unit: mm
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

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
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)
5. No. 2 sun gear (No. of teeth: 19)
6. Drive gear (No. of teeth: 19) Specifications
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

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 —

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

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
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

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

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
+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

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
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 —

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

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
Clearance between shaft and size clearance limit
–0.140 +0.375 0.375 –

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

Unit: mm

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 —

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

(2/2)
fl P portion shows the link of bushing press fitting end.
10-20 PC750, 800-6

Unit: mm
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

DOUBLE SHOE
Unit: mm

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

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

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

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

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

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

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

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

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

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

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

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 controller 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

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

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

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

6. No. 1 pump front CO, NC valve
10-42 PC750, 800-6

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
Pdr2 : CO, NC valve drain OUT port
Pecn : CO, NC valve output pressure OUT port
PC750, 800-6 10-43

7. No. 1 pump rear CO, NC valve
10-44 PC750, 800-6

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
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

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

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

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

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

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

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
P1 : Pilot pressure IN port
PC750, 800-6 10-51

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

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

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
10-54 PC750, 800-6

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

PC750, 800-6 10-59

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

10-62 PC750, 800-6

Unit: mm

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
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

PC750, 800-6 10-65

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

10-68 PC750, 800-6

Unit: mm

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)

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

1. Orifice
2. Check valve
3. Spring
4. Spool return spring
5. Body
6. Spool
7. Cover
PC750, 800-6 10-71

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

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

Unit: mm
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

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

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
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

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

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

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

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

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

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

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

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

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

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

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

Unit: mm

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

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

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

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

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

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

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

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

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

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
PC750, 750LC, 800-6 STD
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-108 PC750, 800-6

(3)
Unit: mm
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

PC750SE, 800SE-6
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-110 PC750, 800-6

Unit: mm
Tolerance
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
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

LOADING SHOVEL SPECIFICATION (with bucket link)

PC750-6
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-111-1 PC750, 800-6

(3)
BOTTOM DUMP CYLINDER
Unit: mm
Tolerance
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

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)
LOADING SHOVEL SPECIFICATION (without bucket link)

PC750-6
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-111-3 PC750, 800-6

(3)
BOTTOM DUMP CYLINDER
Unit: mm
Tolerance
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

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
PC750-6
PC750LC-6
10-112 PC750, 800-6

(3)
Unit: mm
Tolerance
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
3 mounting pin of arm and link 115 –0.090 +0.271 0.441 1.5

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

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

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

PC750SE-6
PC800, 800SE-6
10-114 PC750, 800-6

Unit: mm
Tolerance
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

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
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

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

LOADING SHOVEL SPECIFICATION (with bucket link)

PC750-6
10-115-1 PC750, 800-6

(3)
Unit: mm
Tolerance
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 –
–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 –

–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)
LOADING SHOVEL SPECIFICATION (without bucket link)

PC750-6
10-115-3 PC750, 800-6

(3)
Unit: mm
Tolerance
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 –
–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

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

2. BUCKET
10-118 PC750, 800-6

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

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

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

Engine controller
10-124 PC750, 800-6

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
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

MACHINE CONTROL SYSTEM DIAGRAM
PC750, 800-6 10-127

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

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

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

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

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

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

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

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

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

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

5. Swing control system
Function
• The system is provided with a swing lock
and swing holding brake function.
10-138 PC750, 800-6

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

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

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

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

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

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

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

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

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

• 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

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

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

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

7) Pump controller
10-152 PC750, 800-6

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

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

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

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

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

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

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

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

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


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


PC800-6
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
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

45 – 55°C
· In D.H mode
· Swing one turn, then measure
time taken to swing next 5 turns
PC750, 800-6 20-5


PC800-6
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.
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)

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)

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


PC800-6
Work equipment posture
45°
BKP00106

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
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

45 – 55°C
· Lock shoes and relieve travel
circuit.
· At each side
PC750, 800-6 20-7


PC800-6
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
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
OUT
PC800: PC800:
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)

PC800-6
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:
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 — —
(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
45 – 55°C
Note: Include cylinder cushion operating time.
PC750, 800-6 20-9

(3)

PC800-6
BKP00115
Arm Max. 5 Max. 5
· Stop arm suddenly and
measure time taken for arm to
stop
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
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.
(PC750 Loading shovel)
45 – 55°C
Internal oil leakage

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)
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

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.

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

resistance

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

resistance

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

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

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


tem component No. method Judgment table conditions
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
resistance
Measure 2) Disconnect
Fuel supply pump PCV1 Between (1) and (2) 2.3 – 5.3 Ω connector
PCV1 (male) PCV1.

resistance
Measure
2) Disconnect
Fuel supply pump PCV2 Between (1) and (2) 2.3 – 5.3 kΩ connector
PCV2 (male) PCV2.

resistance

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

resistance

Measure
CN2 2) Disconnect
(male)

resistance
Measure
2) Disconnect
No. 3 fuel injector CN3 Between (1) and (2) 0.4 – 1.1 Ω connector CN3.
(male)

resistance

Measure
CN4 2) Disconnect
(male)

below, it is normal
resistance
switch OFF.
Measure
CN5 2) Disconnect
(male)
PC750, 800-6 20-13


resistance
Measure
CN6 2) Disconnect
(male)

Measure
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.

Measure
voltage

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

Measure

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

2) Turn starting
switch ON.

Measure

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

Measure
voltage
Starting switch connector E14.

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

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)

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


Judgment table
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)
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

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

continuity
2) Disconnect
Measure
Swing holding When switch When switch harness.

SW01
brake release is OFF is ON
switch (switch)
Between (4) adn (6) No continuity Continuity
PC750, 800-6 20-15


Judgment table
When switch When switch 2) Disconnect
is OFF is ON connector C05.
Measure continuity
Emergency pump C05
drive switch (male) Between (4) and (2) Continuity No continuity

resistance
Measure

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

Measure resistance
Between Between Between Between 2) Disconnect

connector C09.
(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

resistance
Measure

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

resistance
Measure

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

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

resistance
Measure

Travel speed V06 2) Disconnect
solenoid valve (male) Between (1) and (2) 20 – 60 Ω connector V06.
20-16 PC750, 800-6


Judgment table
resistance
Measure
Straight-travel V03 2) Disconnect
solenoid valve (male)
resistance
CO cancel V07 Measure 2) Disconnect
solenoid valve (male)

resistance
Measure
Swing priority 2) Disconnect

selector solenoid V01 Between (1) and (2) 20 – 60 Ω connector V01.
valve (male)
If the condition is within the range shown 1) Turn step light

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

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

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.

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


Judgment table
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


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.

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

Measure
voltage
2) Insert T-
S-NET C17 Between (4), (12) and chassis 4–8V adapter.
20-18 PC750, 800-6


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

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.

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.
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).

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.)

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


Judgment table
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)

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

Measure
adapter.
voltage
Swing priority Swing priority selector

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

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

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.

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


Judgment table
Measure
2) Wait for at
voltage
Step light 0–3V 1) least 1 minute
power source
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.

resistance

Measure
V03 2) Disconnect
(male) Between (1) and (2) 20 – 60 Ω connector V03.
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)

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

resistance

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

resistance

Measure
V09 (male)
Boom shockless (RAISE) 2) Disconnect
Between (1) and (2) 20 – 60 Ω connectors
solenoid V10 (male)
(LOWER) V09, V10.
PC750, 800-6 20-21


Judgment table
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

continuity
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


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

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.

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

Monitor system

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.

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.

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


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
3
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.
• 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.

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.
• 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.
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.

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).

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.

leakage.
with color checker.
6. Start the engine and run it at high idling.

leakage.
with color checker.
20-40 PC750, 800-6

TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

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

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

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.
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

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

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

PISTON PUMP CONTROL
PRESSURE
1. TVC valve output pressure
Measuring
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

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
• 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

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

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)
follows.
WISE.
To DECREASE pressure, turn COUNTER-
CLOCKWISE.
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)
follows.
WISE.
CLOCKWISE.
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

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.
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

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.
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
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

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

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

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

20-66 PC750, 800-6

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.
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.
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

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

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

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

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

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

‡ 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

‡ 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

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

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

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


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


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
PC750, 800-6 20-115

20-116 PC750, 800-6

PC750, 800-6 20-117

20-118 PC750, 800-6

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

— • 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

No. SWP-type connector

of
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

No. SWP-type connector

of
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

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

No. S-type connector

of
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

No. S-type connector

of
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

No. MIC-type connector

of
T-adapter
Part No.
Body part No.: 79A-222-2640 Body part No.: 79A-222-2630

7 —
(Q’ty: 5) (Q’ty: 5)

11 —
(Q’ty: 5) (Q’ty: 5)
5 799-601-2710

(Q’ty: 5) (Q’ty: 5)
9 799-601-2950

(Q’ty: 5) (Q’ty: 5)
13 799-601-2720

(Q’ty: 2) (Q’ty: 2)
20-126 PC750, 800-6

No. MIC-type connector

of
pins Part No.
17 799-601-2730

(Q’ty: 2) (Q’ty: 2)
21 799-601-2740

(Q’ty: 2) (Q’ty: 2)
—
(Q’ty: 50) (Q’ty: 50)
PC750, 800-6 20-127

No. AMP040-type connector

of
pins Part No.
8 799-601-7180
— Housing part No.: 79A-222-3430

(Q’ty: 5)
12 799-601-7190

(Q’ty: 5)
16 799-601-7210

(Q’ty: 5)
20 799-601-7220

(Q’ty: 5)
fl Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-128 PC750, 800-6

No. AMP070-type connector

of
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

No. L-type connector

of
pins
Part No.
2 —
— —
No. Connector for PA

of
pins Part No.
9 —
— —
No. Bendix MS connector

of
T-adapter
Part No.
10 799-601-3460
— —
20-130 PC750, 800-6

No. KES 1 (Automobile) connector

of
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 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
PC750, 800-6 20-131

No. KES 1 (Automobile) connector

of
pins
Part No.
8 —
08027-10820 (Black) 08027-10870 (Black)
20-132 PC750, 800-6

No. Connector for relay (Socket type)

of
T-adapter
Part No.
5 799-601-7360
— —
6 799-601-7370
— —
PC750, 800-6 20-133

No. F-type connector

of
pins Part No.
4 —
— —
20-134 PC750, 800-6

[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
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
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


(shell
size T-adapter
Part No.
799-601-9230
18-20 Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102

799-601-9230
Part No.: 08191-32201, 08191-32202 Part No.: 08191-33101, 08191-33102

799-601-9240
18-21 Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102

799-601-9240
Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102
20-136 PC750, 800-6

(shell
size T-adapter
Part No.
799-601-9250
24-9 Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102

799-601-9250
Part No.: 08191-52201, 08191-52202 Part No.: 08191-53101, 08191-53102

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
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


(shell
size T-adapter
Part No.
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
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
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
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

(shell
size T-adapter
Part No.
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
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

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
4 799-601-9040
6 799-601-9050
20-140 PC750, 800-6

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
12GR:799-601-9110
12B: 799-601-9120
10 12G: 799-601-9130
12BR:799-601-9140
PC750, 800-6 20-141

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
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

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

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
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


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


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)
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.
If the abnormality occurs at the same time in both PCV1 and PCV2, user code [E10] is
displayed.
If the abnormality is serious and the controller all stop is generated, user code [E10] 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

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
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
PC750, 800-6 20-149

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
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
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

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
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


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)
(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


code No.
(1) Starting switch C signal ON (turn switch to START)
(2) Auto-deceleration signal GND connected
85 Engine controller input status
(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

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

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

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

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

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

Abnormality in fuel injection amount adjustment switch signal
Abnormality in engine water temperature (high- temperature) sensor system
Disconnection in fuel supply pump PCV1 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

Common rail fuel high-pressure abnormality 1

Abnormality in boost pressure sensor system
Supply pump non-force feed abnormality 1

Disconnection in No. 1 fuel injector system

Abnormality in common rail fuel pressure
Abnormality in fuel control dial system
Power source system abnormality 1

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
Bucket DUMP
Bucket CURL
2-stage relief
Travel speed
Boom RAISE
R.H. travel
L.H. travel
CO cancel
Arm OUT
Model code
Arm IN
Swing
1 2 3 4 5 6 1 2 5 3 1 2 3 4 5 6
User code LED E02 E03 — — Bit pattern Monitoring code

Failure mode
Service code OFF 232 233 203 213 201 211 202 212 204 214 205 215 206 216 217 227 20 21 23 02 10 13
▲ ▲ ‡ ‡
All work equipment,
Speeds of all work equipment, swing, travel are slow or lack power 9 9 9 H-1
travel, swing
Engine speed drops or engine stalls o o o ‡ ‡ 9 9 H-2

No work equipment, travel, swing move H-3
Abnormal noise generated (around pump) H-4
Auto-deceleration does not work o 9 9 9 9 9 9 9 9 9 H-5
Boom is slow or lacks power o o 9 9 9 9
Arm is slow or lacks power o o 9 9 9 H-6
Bucket is slow or lacks power
Work equipment
o o 9 9 9
Boom does not move
Arm does not move H-7
Bucket does not move
Excessive hydraulic drift H-8
Excessive time lag H-9
Excessive shock when stopping boom (shockless switch ON) 9 C-19, H-10
Machine push-up function does not work properly 9 C-18, H-11
Travel deviation is excessive during compound operations o o 9 9 9 9 9 9 9 9 9 9 H-12
Machine deviates naturally to one Direction of deviation is same in FORWARD and REVERSE
Travel system
H-13
side during travel operations Direction of deviation is different in FORWARD and REVERSE
Deviation is excessive when starting H-14
Travel speed is slow o o 9 9 9 H-15
Travel speed does not switch or is faster (slower) than set speed o o o H-16
Does not move (one side only) H-17
Both left and right o o 9
Does not swing H-18
One direction only
Swing speed is slow or Both left and right 9
H-19
swing acceleration is poor One direction only
Swing speed is slow or swing acceleration is poor during compound operations with arm or bucket H-20
Swing system
When swing priority is ON, swing speed is slow or swing acceleration is poor during compound operations with boom RAISE o o H-21
Excessive overrun when Both left and right
H-22
stopping swing One direction only
Excessive shock when stopping swing H-23
Excessive abnormal noise when stopping swing H-24
Excessive hydraulic drift of When swing holding brake is released
H-25
swing When swing holding brake is applied 9 9 9 9 9 9 9 9
Troubleshooting code when service code is displayed C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13 C-14 C-15 C-16 C-17 — — — — — — — — — — — — — — — — — — — — —
Troubleshooting code when there is abnormality in monitoring code check — — — — — — — — — — — — — — — — — F-1 F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-11 — — — — — — — — — — —
o This shows applicable item for service code
When heavy lift switch is ON and boom is operated independently (applicable item for service code)
9 This shows items to inspect with monitoring or machine monitor
▲ CO is canceled in DH mode
[Judgement]
1) If a service code is being displayed on the monitor panel ..... go to troubleshooting [E2: ,
E3: ] for the pump controller.
2) If no service code is displayed on the monitor panel, and the upper structure does not swing: .
There is a signal .... Go to troubleshooting H-25 of
Check pump controller
mechanical system
• input signal (Check in
monitoring mode)
There is no signal .. Go to troubleshooting F– of pump
controller input signal system
(F mode for applicable system)
20-160 PC750, 800-6

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component Service code
E117, E118,
N- Troubleshooting of communication abnormality system
E218, E955
E- Troubleshooting of electrical system for engine throttle, pump controller (governor control system) E9- group
E2- group
C- Troubleshooting of electrical system for engine throttle, pump controller (pump control system)
E3- group
F- Troubleshooting of engine throttle, pump controller (input signal system) —
H- Troubleshooting of hydraulic, mechanical system —
M- Troubleshooting of machine monitor E1- group
2. Method of using YES/NO troubleshooting flowchart

1) Troubleshooting code number and problem
The title at the top of the troubleshooting chart gives the failure code and problem with the
machine.
Example: M-13 Abnormality in buzzer
2) General precautions
When carrying out troubleshooting, precautions are given at the top of the page under the title
and marked with fl.
The common precautions are marked fl in the Contents, so they must always be followed
checked before carrying out the troubleshooting.
Example: fl Before carrying out troubleshooting, check that all the related connectors are
properly inserted.
fl Always connect any disconnected connectors before going on the next step.
3) Distinguishing conditions
Even with the same problem, the method of troubleshooting may differ according to the
model, component, or problem. In such cases, the failure mode is further divided into sections
marked with small letters (for example, a)), so go to the appropriate section to carry out
troubleshooting.
If the troubleshooting table is not divided into section, start troubleshooting from the first
check item in the flowchart.
Example: a) When starting switch is turned ON (3 sec), buzzer does not sound
b) Buzzer always sounds
4) Method of following troubleshooting chart
NO
• Check or measure the item inside YES
, and according to the answer follow either
the YES line or the NO line to go to the next .
(Note: The number written at the top right corner of the is an index number; it
does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead finally
to the Cause box. Check the cause and take the action given in the Remedy box on the right.
• To the left of the there is (a box formed by a broken line). This contains
the methods for inspection or measurement, and the judgement values.
If the judgement values to the left of the are correct or the answer to the question
inside the is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
• The gives the preparatory work needed for inspection and measurement, and the
judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from the first item.
5) Position of installation, pin number
For details of the connector pin number and check and measurement locations of the connector pin
numbers appearing in the flowchart, see CONNECTOR TYPE AND MOUNTING LOCATION.
PC750, 800-6 20-161

TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING

PROCEDURE
If any abnormality should occur, it is necessary to go to the correct troubleshooting chart in accor-
dance with the judgement table for that type of failure (engine controller and pump controller. For
details of the troubleshooting and troubleshooting procedure, refer to this flow chart.
When carrying out troubleshooting, ask the operator as much as possible about the condition of the
machine, and check the following items before starting.
(1) Condition of controller connection (check with monitoring codes 01 – 08)
(2) Blown fuses
(3) Battery voltage (monitoring mode 32)
(4) Electricity generation (charge input) voltage (monitoring code 43)
The procedure for carrying out check items No. 3 and 4 in the flow chart below is given on the
following pages.
}
E02 (TVC system) E10 (Engine stop system) E15 (Engine system)
YES
E03 (Swing brake system) E11 (Engine control system) Go to Item 2
E0E (Network system) E14 (Fuel dial system)
E100 group: Monitor panel system (M mode) Carry out troubleshooting in applicable mode
Is user code
displayed on
1 YES E200 group: Pump controller system (C mode)
E300 group: Pump controller system (C mode)
E400 group: Engine controller system (E mode)
} (Note: For E117, E118, E218, carry out
troubleshooting of the communication
abnormality system (N mode).)
monitor panel? 6 YES Carry out

troubleshooting
Engine Is engine electrical for engine
system for which
system there is no failure Carry out
5 code display troubleshooting for
2 Is problem in engine electrical
normal?
system.
Is service code YES engine system • Go to flow chart for NO (Use flow chart for
of hydraulic section where there is
displayed on (mechanical) items where there is
NO monitor panel? no abnormality display no display)
system? on judgment table.
4
• After adjusting Hydraulic Carry out
• Operate and Are pump oil pressure, (mechanical) troubleshooting for
check service YES controller input judge from system hydraulic (mechanical)
code. and output system
engine speed.
signals normal?
• Is all work equipment slow and
• Check using does engine speed drop under
3
monitoring code. heavy load?
Are monitor Carry out troubleshooting for
codes 02, 03, NO
input signal system (F mode).
NO 08 normal?
• Check
connection
Carry out troubleshooting
condition of
for communication
S-NET in
NO abnormality system
monitoring
(N comde).
codes
02, 03, 08.
fl For details, see engine throttle, pump controller (governor control system) (pump control system)
in the JUDGEMENT TABLE.
20-162 PC750, 800-6

If there is no abnormality display in the communications system transmitted by S-NET, it can be taken
that the output signal from the monitor panel has been transmitted. However, even if there is no
abnormality display, if the operation is defective, use the following procedure when checking directly.
If any abnormality occurs in the S-NET system, the system is automatically switched to the following
default mode, so be careful when carrying out troubleshooting.
Defaults when communications cannot be carried out for the monitor panel, engine controller,
and pump controller
Set mode Pump controller Engine controller
1 Working mode Abnormality mode DH mode
(equivalent to G mode)
2 Throttle signal FULL —
3 Auto-deceleration ON (deceleration mode) ON (deceleration mode)
4 Coolant temperature signal OFF —
5 Heavy lift OFF —
6 Travel speed Lo —
7 Automatic warming up — —
1. Procedure for checking monitor panel output signal

fl For details of operating the monitoring mode, see MONITOR PANEL DISPLAY AND SPECIAL
FUNCTIONS.
1. Connection status of components
1) Set to the monitoring mode and display monitoring code [08].
2) The time display (bits) will light up to display the components that are connected.
fl Pump controller (1) and engine controller (3) will light up.
2. Checking working mode signal {check No. 2 throttle signal (monitoring code [16]) at the same
time}
2) Switch the working mode as shown in Table 1 and check that the engine speed changes.
Table 1
High idling speed (rpm)
Working mode [The figures in ( ) are the matching point ª]
Approx. 1,980 <lever operated slightly>
DH Approx. 1,880 <idling> (1,770)
Approx. 1,980 <lever operated slightly>

H Approx. 1,880 <idling> (1,730)
G Approx. 1,880 (1,730)
ª mark: When boom RAISE is relieved with heavy lift switch ON
PC750, 800-6 20-163

3. Checking travel speed selection signal

2) Change the travel speed selector switch to Hi, run the engine at 1200 rpm or above, and
check that bit (6) lights up.
4. Checking swing priority mode signal
2) Turn the swing priority switch ON and check that bit (5) lights up.
2. Checking input signal of pump controller

fl Check the input signals for each controller as follows.
• Pump control system
1. Checking input signal
1) Check oil pressure switch
i) Set to the monitoring mode, and display monitoring codes [20] and [21].
ii) Operate each work equipment lever, and check how the bit pattern lights up.
fl For details of the bit pattern chart, see MONITOR PANEL DISPLAY AND SPECIAL
FUNCTIONS.
2) Check speed sensor (check engine speed)
i) Set to the monitoring mode, and display monitoring code [10].
ii) Use the fuel control dial to change the speed, and measure the speed when this is
done.
2. Check output signals

1) No. 2 throttle signal
ii) Switch to the working mode shown in Table 2 and check the change in the monitor
display.
Table 2
Working mode Speed for monitoring display [16] (rpm)
DH 1,980
H 1,980
G 1,880
íii) See Step 2 in the procedure for checking the monitor panel output signal.
20-164 PC750, 800-6

2) Checking ON ↔ OFF solenoid status

ii) Refer to Table 3 and check that the applicable bit lights up.
Table 3 Types of solenoid and conditions for actuation
Code Name of solenoid Actuation condition Bit that lights up
CO cancel D.H mode (1)
Left and right travel ON at same time,

Straight travel swing operated (2)
When either swing or work equipment

Swing holding brake lever operated (3)
23
Heavy lift switch ON and boom RAISE
2-stage relief operated individually (4)
Swing priority Swing priority switch ON (5)

When traveling with travel speed selector
Travel speed selector switch at Hi engine speed (min. 1200) (6)
3) Check TVC solenoid output current

ii) With the starting switch at the ON position, and the engine started (G mode), measure
the current when the fuel control dial is turned to the FULL position.
: 540 ± 30 (mA)
3. Check input signal of engine controller

fl Check the input signals for each controller as follows.
• Engine control system
1) Checking input voltage of fuel control dial
ii) Measure the voltage when the fuel control dial is turned from low idling to high idling.
fl Voltage 0.25 – 4.75 V
PC750, 800-6 20-165

TROUBLESHOOTING OF
COMMUNICATION ABNORMALITY SYSTEM
(N MODE)
Action taken by controller when abnormality occurs and problems on machine ..........................20-202
Electrical circuit diagram for N Mode system .....................................................................................20-204
N-1 [E117, E118 occur at same time] Monitor panel communication abnormality ..................20-205
N-2 [E117, E218 occur at same time] Engine controller communication abnormality .............20-207
N-3 [E118, E955 occur at same time] Pump controller communication abnormality ............... 20-209
PC750, 800-6 20-201

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

OCCURS AND PROBLEMS ON MACHINE
User Service
Abnormal system Nature of abnormality
code code
• When problem occurs at same time as E118
1. Disconnection, defective contact of monitor panel S-
NET
2. Wiring harness of monitor panel S-NET short circuiting
with chassis ground
S-NET communication
3. Defective monitor panel
E117 error with engine
controller • When problem occurs at same time as E218
1. Disconnection, defective contact in wiring harness of
engine controller S-NET
2. Wiring harness of engine controller S-NET short cir-
E0E cuiting with chassis ground
3. Defective engine controller
• When problem occurs at same time as E117: Same as

E117 above
S-NET communication • When problem occurs at same time as E955
error with pump 1. Disconnection, defective contact in wiring harness of
E118
controller pump controller S-NET
2. Wiring harness of pump controller S-NET short circuit-
ing with chassis ground
3. Defective pump controller
• When problem occurs at same time as E117: Same as

— E218 Pump controller S-NET
response overtime error E117 above
Abnormality in engine • When problem occurs at same time as E118: Same as

E0E E955 E118 above
controller S-NET system
20-202 PC750, 800-6

Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
1. Working mode becomes G 1. Operation is carried out in G Mode.
Mode.
2. Displays user code E0E on 2. Lacks power or speed is slow.
monitor panel.

Mode.
2. Displays user code E0E on 2. Lacks power or speed is slow.
monitor panel.

Mode.
2. Lacks power or speed is slow.

Mode.
2. Lacks power or speed is slow.
PC750, 800-6 20-203

TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR N MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR N MODE SYSTEM
20-204 PC750, 800-6

TROUBLESHOOTING N-1
N-1 [E117, E118 occur at same time] Monitor panel communication

abnormality
Cause Remedy
1
• Disconnect P01 and
connect again. Is monitoring code [02], [03] NO
• Turn starting switch ON. display normal?
• See Table 1.
YES
System has been reset —
2
• Turn starting switch ON. Do bits (1) and (3) light up in NO
• See Table 2. monitoring code [08]?
YES
3
• Turn starting switch ON.
When E12 and C17 are disconnected, NO Defective pump controller,
do bits (1), (2), (3), and (4) light up in Replace
• See Table 2. monitoring code [08]? engine controller
YES
• Disconnect P01, C17, 4 Short circuit in wiring harness

Is resistance between P01 (female)
and E12.
(4) (11) and (14), or between (4) NO at side where resistance is not Repair or
• Turn starting switch normal, or short circuit with
OFF. (11) and chassis normal? replace
YES ground connection
• Min. 1 MΩ
Defective monitor panel Replace
5
• Disconnect E12 and Is voltage between E12 (female) (8) NO
C17. (18) and chassis, and between C17
• Turn starting switch ON. (female) (4) (12) and chassis normal?
• Min. 7.5 V
YES Defective controller at side
where bit does not light up in Replace
Item 2
• Disconnect P01, E12, 6 Defective contact or

and C17. Is resistance between P01 (female) (4) and NO
C17 (female) (4), and between P01 (female) disconnection in wiring Repair or
• Turn starting switch harness at side where
(11) and E12 (female) (18) normal? replace
OFF.
YES resistance is not normal
• Max. 1Ω
Table 1
Monitoring code Display
02 Pump controller model code
03 Engine controller model code
fl If the controllers are not connected to the network, the center bits display only (– – –). If the correct
alphanumerics are not displayed (or another model is displayed), the model selection signal of the
controllers is abnormal.
PC750, 800-6 20-205

TROUBLESHOOTING N-1
Table 2
08 Network connection status
• Bits light up when network is connected (12: Pump controller, 34: Engine controller)
fl Checks for disconnection in the network system can be carried out with this monitoring code.
The display does not change when there is a short circuit with the ground. (The normal display is
given.)
N-1 Related electrical circuit diagram
20-206 PC750, 800-6

TROUBLESHOOTING N-2
N-2 [E117, E218 occur at same time] Engine controller communication

abnormality
Cause Remedy
1
• Disconnect E12 and
M94 and connect again. Is monitoring code [03] display NO
• Turn starting switch ON. normal?
• See Table 1.
YES
2
• Turn starting switch ON. Does bit (3) light up in NO
YES
3
• Turn starting switch ON. When E12 is disconnected, NO
• See Table 2.
does bit (3) light up in Defective engine controller Replace
monitoring code [08]?
YES
• Disconnect P01, C17, 4 Short circuit in wiring harness

and E12. Is resistance between E12 (female) NO at side where resistance is not Repair or
• Turn starting switch (8) (18) and (10), or between (8)
(18) and chassis normal? normal, or short circuit with replace
OFF. ground connection
• Min. 1 MΩ YES
5
• Disconnect E12. Is voltage between E12 NO
• Turn starting switch ON. (female) (8)(18) and chassis
• Min. 7.5 V normal?
YES
Defective engine controller Replace

and C17. Is resistance between E12 (female) disconnection in wiring
• Turn starting switch (8) – C17 (female) (12), E12 (female) NO Repair or
(18) – P01 (female) (11) normal? harness at side where replace
OFF. resistance is not normal
• Max. 1 Ω YES
Defective monitor panel and Replace
pump controller
Table 1
03 Engine controller model code
PC750, 800-6 20-207

TROUBLESHOOTING N-2
Table 2
• Bits light up when network is connected (34: Engine controller)

given.)
20-208 PC750, 800-6

TROUBLESHOOTING N-3
N-3 [E118, E955 occur at same time] Pump controller communication

abnormality
Cause Remedy
• Disconnect C17 and 1
connect again. Is monitoring code [02] display NO
• Turn starting switch ON. normal?
• See Table 1.
YES
2
• Turn starting switch ON. Does bit (1) light up in NO
YES
3
• Turn starting switch ON. When C17 is disconnected, NO
• See Table 2.
does bit (1) light up in Defective pump controller Replace
monitoring code [08]?
YES
• Disconnect P01, C17, 4

Is resistance between C17 Short circuit in wiring harness Repair or
and E12. NO
• Turn starting switch (female) (4) (12) and chassis at side where resistance is not replace
OFF. normal? normal
• Min. 1 MΩ YES
5
• Disconnect C17. Is voltage between C17 NO
• Turn starting switch ON. (female) (4)(12) and chassis
• Min. 7.5 V normal?
YES
Defective pump controller Replace

and C17. Is resistance between C17 (female) disconnection in wiring
(4) – P01 (female) (4), C17 (female) NO Repair or
• Turn starting switch harness at side where
(12) – E12 (female) (8) normal? replace
OFF. resistance is not normal
• Max. 1 Ω YES
Defective monitor panel and Replace
pump controller
Table 1
02 Pump controller model code
PC750, 800-6 20-209

TROUBLESHOOTING N-3
Table 2
• Bits light up when network is connected (12: Pump controller)

given.)
20-210 PC750, 800-6

TROUBLESHOOTING OF
ENGINE CONTROLLER SYSTEM
(E MODE)
Action taken by controller and condition of machine when error code is displayed ....................20-252
Judgement table for engine controller and engine related parts .....................................................20-260
Electrical circuit diagram of E mode system .......................................................................................20-262
E- 1 [E91b] (Abnormality in engine speed Ne sensor system) is displayed ..............................20-264
E- 2 [E91C] (Abnormality in engine G rotation sensor system) is displayed ............................ 20-265
E- 3 [E920] (Abnormality in model selection system) is displayed ............................................20-266
E- 4 [E922] (Engine overrun) is displayed ......................................................................................20-267
E- 5 [E924] (Drop in engine oil pressure) is displayed .................................................................20-268
E- 6 [E931] (Abnormality in fuel control dial sensor system) is displayed ................................20-269
E- 7 [E934] (Abnormality in engine water high-temperature sensor system)
is displayed ....................................................................................................................20-270
E- 8 [E936] (Abnormality in engine oil pressure switch system) is displayed ..........................20-271
E- 9 [E93C] (Abnormality in boost pressure sensor system) is displayed .................................20-273
E-10 [E93d] (Abnormality in fuel temperature sensor system) is displayed ..............................20-274
E-11 [E954] (Short circuit in starting switch C system) is displayed ...........................................20-275
E-12 [E955] (Abnormality in network system) is displayed ..........................................................20-275
E-13 [E956] (Power source system abnormality 1) is displayed ..................................................20-276
E-14 [E957] (Power source system abnormality 2) is displayed ..................................................20-278
E-15 [E95A] (Abnormality in fuel injection amount adjustment switch signal)
is displayed ....................................................................................................................20-278
E-16 [E96A] (Abnormality in engine water low-temperature sensor system)
is displayed ....................................................................................................................20-279
E-17 [E970] (Excess current in fuel supply pump PCV1 system) is displayed ........................... 20-280
E-18 [E971] (Excess current in fuel supply pump PCV2 system) is displayed ........................... 20-281
E-19 [E974] (Disconnection in fuel supply pump PCV1 system) is displayed ............................ 20-282
E-20 [E975] (Disconnection in fuel supply pump PCV2 system) is displayed ............................ 20-283
E-21 [E977] (Abnormality in common rail fuel pressure sensor system) is displayed .............20-284
E-22 [E979] (Common rail fuel high pressure abnormality 1) is displayed
[E97A] (Common rail fuel high pressure abnormality 2) is displayed ................................20-285
E-23 [E97b] (Fuel supply pump non-force feed 1) is displayed
[E97C] (Fuel supply pump non-force feed 2) is displayed ...................................................20-286
E-24 [E97d] (Abnormality in common rail fuel pressure) is displayed .......................................20-288
E-25 [E980] (Defective engine controller) is displayed ..................................................................20-288
E-26 [E981] (Disconnection in No. 1 fuel injector system) is displayed .....................................20-289
E-32 [E98A] (Short circuit in No. 1, No. 2, No. 3 fuel injector system) is displayed .................20-295
E-33 [E98b] (Short circuit in No. 3, No. 4, No. 5 fuel injector system) is displayed .................20-299
PC750, 800-6 20-251

ACTION TAKEN BY CONTROLLER AND CONDITION OF
TROUBLESHOOTING MACHINE WHEN ERROR CODE IS DISPLAYED

MACHINE WHEN ERROR CODE IS DISPLAYED
User Service Abnormal
Nature of abnormality
code code system
1. Defective contact, disconnection, short circuit, or short circuit with ground
inside Ne rotation sensor
E11 Abnormality in engine 2. Defective contact, disconnection, or short circuit with ground in wiring
E91b Ne rotation sensor harness between controller E11 (5) (+) and Ne rotation sensor NE (1)
E10 system 3. Defective contact, disconnection, or short circuit with ground in wiring
harness between controller E11 (12) (–) and Ne rotation sensor NE (2)
1. Defective contact, disconnection, short circuit, or short circuit with ground
in wiring harness inside G rotation sensor
Abnormality in engine 2. Defective contact, disconnection, or short circuit with ground in wiring
E11 E91C G rotation sensor harness between controller E12 (1) (+) and G rotation sensor G (1)
E10 system 3. Defective contact, disconnection, or short circuit with ground in wiring
harness between controller E12 (9) (–) and G rotation sensor G (2)
1. Defective machine model selection connector
2. Defective contact, disconnection, or short circuit with ground in wiring
harness between controller E14 (13) and machine model selection con-
nector E09 (1)
Abnormality in 3. Defective contact, disconnection, or short circuit with ground in wiring
E11 E920 machine model harness between controller E14 (14) and machine model selection con-
selection system nector E09 (2)
harness between controller E14 (15) and machine model selection con-
nector E09 (3)
— E922 Overrun 1. Engine speed goes above operating range

1. Engine oil pressure goes below operating range
2. Defective engine oil low-pressure sensor
3. Defective engine oil high-pressure sensor
Drop in engine oil 4. Short circuit with ground in wiring harness between controller E14 (5)
E11 E924 pressure and oil low-pressure sensor PSL
5. Short circuit with ground in wiring harness between controller E14 (6)
and oil high-pressure sensor PSH
1. Defective fuel control dial
harness between controller E11 (4) (power source) and fuel control dial
Abnormality in fuel E06 (1)
E14 E931 control dial system 3. Defective contact, disconnection, or short circuit with ground in wiring
harness between controller E11 (6) (signal) and fuel control dial E06 (2)
harness between controller E11 (11) (GND) and fuel control dial E06 (3)
1. Defective engine water high-temperature sensor

Abnormality in engine harness between controller E12 (4) (signal) and water high-temperature
E934 water high-tempera- sensor TWH (1)
E15 ture sensor system 3. Defective contact, disconnection or short circuit with ground in wiring
harness between controller E12 (10) (GND) and water high-temperature
sensor TWH (2)
1. Defective oil low-pressure sensor

2. Defective oil high-pressure sensor
Abnormality in engine 3. Defective contact, disconnection, or short circuit with ground in wiring
oil pressure switch harness between controller E14 (5) and oil low-pressure sensor PSL
E15 E936 4. Defective contact or disconnection in wiring harness between controller
system
E14 (6) and oil low-pressure sensor PSH
1. Defective boost pressure sensor

harness between controller E12 (2) (power source) and boost pressure
sensor PIM (1)
Abnormality in boost 3. Defective contact, disconnection, or short circuit with ground in wiring
E11 E93C pressure sensor harness between controller E11 (3) (signal) and boost pressure sensor
system PIM (2)
harness between controller E12 (10) (GND) and boost pressure sensor
PIM (3)
20-252 PC750, 800-6

Problem that appears

Condition when normal Action by controller on machine
• Sensor resistance value 1. Displays user code [E11] (when occur- 1. Reduces output (when prob-
Between NE (1) and (2): 85 – 210 Ω ring independently) or [E10] (when E91C lem occurs independently)
occurs at same time) 2. Engine stops during opera-
2. Limits output for operation (when prob- tion (when E91C occurs at
lem occurs independently) same time)
3. Control of the system becomes impos- 3. Engine cannot be started (when
sible (when E91C occurs at same time) E91C occurs at same time)
• Sensor resistance value 1. Displays user code [E11] (when occur- 1. Output is reduced (when prob-
Between G (1) and (2): 1.4 k – 3.5 kΩ ring independently) or [E10] (when E91b lem occurs independently)
occurs at same time) 2. Engine stops during opera-
2. Limits output for operation (when prob- tion (when E91b occurs at
lem occurs independently) same time)
3. Control of the system becomes impos- 3. Engine cannot be started (when
sible (when E91C occurs at same time) E91b occurs at same time)
• Resistance in ground connection circuit 1. Displays user code [E11] 1. Output is reduced
Between E14 (female) (13) (15) and ground: 2. Carries out operation under normal con-
Max. 1 Ω trol
• Resistance in ground cut-off circuit
Between E14 (female) (14) and ground:
Min. 1 MΩ
1. Stops fuel injection until engine speed 1. Engine speed varies abnor-
goes down to operating range mally
• Low-pressure switch resistance value 1. Displays user code [E11] 1. Runs at low idling.
Between PSL and ground 2. Limits output for operation
Engine stopped: Max. 1 Ω
Engine above 600 rpm: Min. 1 MΩ
• High-pressure switch resistance value
Between PSH and ground
• Sensor power source voltage 1. Displays user code [E14] 1. Fixed at high idling (when
Between E11 (4) and (11): 4.6 – 5.4 V 2. Actuated with throttle signal 100% problem occurs indepen-
• Sensor signal voltage (when problem occurs independently dently)
Between E11 (6) and (11): 0.3 – 4.7 V and at same time) 2. Fixed at low idling (when
3. Actuated with throttle signal 0% (when E924 and E936 occur at same
E924 and E936 occur at same time) time)
• Sensor resistance value (water temperature: 1. Displays user code [E15] 1. Fixes water temperature sig-
10 – 100°C) 2. Carries out operation under normal con- nal output to machine at 90°C
Between TWH (1) and (2): 90 k – 3.5 kΩ trol
• Low-pressure switch resistance value 1. Displays user code [E15] 1. Operates normally
Between PSL and ground 2. Carries out operation under normal con-
Engine stopped: Max. 1 Ω trol
• High-pressure switch resistance value
Between PSH and ground
• Sensor power source voltage 1. Displays user code [E11] 1. Operates normally
Between PIM (1) and (3): 4.6 – 5.4 V
• Sensor signal voltage
Between PIM (2) and (3): 0.3 – 4.7 V
PC750, 800-6 20-253


code code system
1. Defective fuel temperature sensor
Abnormality in fuel harness between controller E12 (11) (signal) and fuel temperature sen-
E15 E93d temperature sensor sor THL (1)
system 3. Defective contact or disconnection in wiring harness between control-
ler E12 (10) (GND) and fuel temperature sensor THL (2)
1. Defective starting switch

— E954 Short circuit in starting 2. Short circuit with power source in wiring harness between controller
switch C signal system E14 (2) and starting switch terminal C
E955 Abnormality in
E0E network system
1. Defective power source relay

harness between starting switch terminal ACC and power source relay
R24 (1)
3. Defective contact or disconnection in wiring harness between power
Power source system source relay R24 (2) and ground
E10 E956 abnormality 1 4. Defective contact, disconnection, or short circuit with ground in wiring
harness between battery relay – circuit breaker 8 – power source relay
R24 (3)
harness between controller E17 (6) (14) and power source relay R24 (5)
1. Defective power source relay

Power source system 2. Short circuit with power source in wiring harness between controller
E15 E957 abnormality 2 E17 (6) (14) and power source relay R24 (5)
Abnormality in fuel 1. Defective setting of fuel injection amount adjustment switch
— E95A injection amount 2. Defective engine controller
adjustment switch signal
1. Defective engine water low-temperature sensor

Abnormality in engine harness between controller E12 (3) (signal) and water low-temperature
E15 E96A water low-temperature sensor TWL (1)
sensor system 3. Defective contact or disconnection in wiring harness between control-
ler E12 (10) (GND) and water low-temperature sensor TWL (2)
1. Defective fuel supply pump PCV1

2. Short circuit with ground or short circuit with power source in wiring
Overcurrent in fuel harness between controller E17 (10) and PCV1 solenoid PCV1 (1)
E11 E970 supply pump PCV1 3. Short circuit with power source in wiring harness between controller
E10 system E17 (11) and PCV1 solenoid PCV1 (2)

Overcurrent in fuel harness between controller E17 (4) and PCV2 solenoid PCV2 (1)
E11 E971 supply pump PCV2 3. Short circuit with power source in wiring harness between controller
E10 system E17 (12) and PCV2 solenoid PCV2 (2)

2. Defective contact or disconnection in wiring harness between control-
Disconnection in fuel ler E17 (10) and PCV1 solenoid PCV1 (1)
E11 supply pump PCV1 3. Defective contact, disconnection, or short circuit with ground in wiring
E10 E974
system harness between controller E17 (11) and PCV1 solenoid PCV1 (2)

Disconnection in fuel ler E17 (4) and PCV2 solenoid PCV2 (1)
E11 E975 supply pump PCV2
E10 3. Defective contact, disconnection, or short circuit with ground in wiring
system harness between controller E17 (12) and PCV2 solenoid PCV2 (2)
20-254 PC750, 800-6


• Sensor resistance value 1. Displays user code [E15] 1. Operates normally.
(fuel temperature: 10 – 100°C) 2. Carries out operation under normal con-
Between THL (1) and (2): 9 k – 0.3 kΩ trol
• Starting switch C signal voltage 1. Carries out operation under normal con- 1. Operates normally 10 sec-
Between E14 (2) and ground trol onds after engine starts.
Starting switch at ON: Max. 1 V
Starting switch at START: 20 – 30 V
1. Displays user code [E0E]
• Power source voltage 1. Displays user code [E10] 1. Engine stops during opera-
Between E17 (6) (14) and (5) (13) tion
Starting switch at ON: 20 – 30 V 2. Engine cannot be started.
• Power source voltage 1. Displays user code [E15] 1. Operates normally

Between E17 (6) (14) and (5) (13) 2. Carries out operation under normal con-
Starting switch at OFF: Max. 8 V trol
• Either fuel injection amount adjustment 1. Carries out operation under normal con- 1. Fuel injection amount adjust-
switch 1 or 2 of controller is set to [F] trol ment setting cannot be
changed
• Sensor resistance value (water tempera- 1. Displays user code [E15] 1. Exhaust gas color at low
ture: 10 – 100°C) 2. Carries out operation under normal con- temperatures is poor.
Between TWL (1) and (2): 9 k – 0.3 kΩ trol 2. Starting ability at low tem-
peratures is poor.
• Solenoid resistance value 1. Displays user code [E11] (when occur- 1. Operates normally (when
Between PCV1 (1) and (2): 2.3 – 5.3 Ω ring independently) or [E10] (when E971 problem occurs indepen-
occurs at same time) dently)
2. Stops output to PCV1 (when problem 2. Stops engine (when E971
occurs independently) occurs at same time)
3. Stops output to PCV1 and PCV2 (when
E971 occurs at same time)
PC750, 800-6 20-255


code code system
1. Defective common rail fuel pressure sensor
harness between controller E12 (2) (power source) and fuel pressure
Abnormality in sensor PFUEL (1)
common rail fuel 3. Defective contact, disconnection, or short circuit with ground in wiring
E11 E977 pressure sensor harness between controller E11 (1) (signal) and fuel pressure sensor
system PFUEL (2)
harness between controller E12 (10) (GND) and fuel pressure sensor
PFUEL (3)
1. Viscosity of fuel is too high (unsuitable fuel)
Common rail fuel high- 2. Defective overflow valve
E11 E979 pressure abnormality 1 3. Defective pressure limiter
4. Defective common rail fuel pressure sensor
5. Clogged overflow piping
fl See E979
Common rail fuel high-
E11 E97A pressure abnormality 2
1. Defective fuel low-pressure circuit (etc.)

2. Defective fuel supply pump PSV
Supply pump non-force 3. Defective pressure limiter
E11 E97b feed abnormality 1 4. Defective common rail fuel pressure sensor
5. Defective fuel injector
6. Leakage from fuel high-pressure piping
Supply pump non-force fl See E97b

E11 E97C feed abnormality 2
fl See E979
Abnormality in
E11 E97d common rail fuel
pressure

ler E17 (5) (13) and ground
E11 Abnormality in
E10 E980 controller
1. Defective No. 1 fuel injector solenoid

ler E16 (7) (–) and No. 1 injector CN1 (1)
E11 E981 Disconnection in No. 1 3. Defective contact or disconnection in wiring harness between control-
E10 fuel injector system ler E16 (8) (+) and No. 1 injector CN1 (2)

E11 E982 Disconnection in No. 2 3. Defective contact or disconnection in wiring harness between control-
E10 fuel injector system ler E16 (10) (+) and No. 2 injector CN2 (2)

E11 Disconnection in No. 3 3. Defective contact or disconnection in wiring harness between control-
E10 E983
fuel injector system ler E16 (9) (+) and No. 3 injector CN3 (2)
20-256 PC750, 800-6


• Sensor power source voltage 1. Displays user code [E11] 1. Output is reduced
Between PFUEL (1) and (3): 4.6 – 5.4 V 2. Limits output with open control
• Sensor signal voltage
Between PFUEL (2) and (3): 0.3 – 4.7 V
1. Displays user code [E11] 1. Output is reduced

2. Operation carried out with limited out-
put

2. Operation carried out with limited en- 2. Engine speed is reduced
gine speed and output
2. Sets engine output to delayed
3. Operation carried out with limited out-
put

2. Operation carried out with limited en- 2. Engine speed is reduced
gine speed and output
1. Displays user code [E11] 1. Engine does not run at high
2. Carries out operation under normal con- idling speed when there is
trol no load
2. Engine stops when a large
load is applied
1. Displays user code [E11] (when occur- 1. Engine does not run at high
ring independently) or [E10] (when E98A, idling speed when there is
E98b occur at same time) no load
2. Operation carried out with limited out- 2. Engine stops when a large
put load is applied
3. Engine stops during opera-
tion
4. Engine cannot be started
• No. 1 injector resistance value 1. Displays user code [E11] (when occur- 1. Output is reduced (when
Between CN1 (1) and (2): 0.4 – 1.1 Ω ring independently) or [E10] (when E982 problem occurs indepen-
to E986 occur at same time) dently)
2. Stops output to No. 1 injector (when 2. Engine stops (when E982 to
problem occurs independently) E986 occur at same time)
3. Stops output to fuel supply pump, all
fuel injectors (when E982 to E986 occur
at same time)
at same time)
at same time)
PC750, 800-6 20-257


code code system
E10 E984 fuel injector system ler E17 (9) (+) and No. 4 injector CN4 (2)


1. Defective No. 1 fuel injector

harness between controller E16 (7) (+) and No. 1 injector CN1 (1)
harness between controller E16 (8) (–) and No. 1 injector CN1 (2)
Short circuit in No. 1, harness between controller E16 (4) (+) and No. 2 injector CN2 (1)
E11 E98A No. 2, No. 3 fuel 7. Short circuit with ground or short circuit with power source in wiring
E10 injector system harness between controller E16 (10) (–) and No. 2 injector CN2 (2)

Short circuit in No. 4, harness between controller E17 (1) (+) and No. 5 injector CN5 (1)
E11 E98b No. 5, No. 6 fuel 7. Short circuit with ground or short circuit with power source in wiring
E10 injector system harness between controller E17 (7) (–) and No. 5 injector CN5 (2)
20-258 PC750, 800-6


at same time)
at same time)
at same time)
• No. 1 injector resistance value 1. Displays user code [E11] (when occur- 1. Output is greatly reduced
Between CN1 (1) and (2): 0.4 – 1.1 Ω ring independently) or [E10] (when E98b (when problem occurs inde-
• No. 2 injector resistance value occurs at same time) pendently)
Between CN2 (1) and (2): 0.4 – 1.1 Ω 2. Stops output to No. 1, No. 2, No. 3 fuel 2. Engine stops (when E98b
• No. 3 injector resistance value injectors (when problem occurs indepen- occurs at same time)
Between CN3 (1) and (2): 0.4 – 1.1 Ω dently)
fuel injectors (when E98b occurs at same
time)
• No. 4 injector resistance value 1. Displays user code [E11] (when occur- 1. Output is greatly reduced
Between CN4 (1) and (2): 0.4 – 1.1 Ω ring independently) or [E10] (when E98A (when problem occurs inde-
• No. 5 injector resistance value occurs at same time) pendently)
Between CN5 (1) and (2): 0.4 – 1.1 Ω 2. Stops output to No. 4, No. 5, No. 6 fuel 2. Engine stops (when E98A
• No. 6 injector resistance value injectors (when problem occurs indepen- occurs at same time)
Between CN6 (1) and (2): 0.4 – 1.1 Ω dently)
fuel injectors (when E98A occurs at same
time)
PC750, 800-6 20-259

JUDGEMENT TABLE FOR ENGINE CONTROLLER
TROUBLESHOOTING AND ENGINE RELATED PARTS
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE

RELATED PARTS
Abnormality in engine oil pressure switch system

Abnormality in engine Ne rotation sensor system
Abnormality in engine water temperature (high- temperature) sensor system

Abnormality in machine model selection system
Abnormality in engine G rotation sensor system
Abnormality in boost pressure sensor system

Abnormality in fuel control dial system
Drop in engine oil pressure
Overheat
Overrun
User code E11 E11
— E10 E10 E11 — E11 E14 E15 E15 E11
Service 108 91b 91C 920 922 924 931 934 936 93C
code
No. Failure mode
1 Engine does not start ‡ ‡ ‡
Starting ability Exhaust gas is emitted but engine does not start, or is difficult to start
2 is poor No exhaust gas is emitted
3 Engine stops during operation ‡ ‡ ‡ ‡
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
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
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
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) ‡
16 Oil consumption is excessive, or exhaust gas is blue
17 Oil becomes dirty prematurely
18 Oil is mixed in coolant
19 Engine oil pressure caution lamp lights up ‡
20 Oil level rises
21 Coolant temperature rises too high ‡
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
code
20-260 PC750, 800-6

Abnormality in fuel temperature sensor system
‡
‡
Short circuit in starting switch C signal system
Abnormality in network system
‡
‡ ‡
‡
‡
‡ ‡
‡
‡
‡
PC750, 800-6
‡ ‡‡
‡ ‡‡
‡
Abnormality in fuel injection amount adjustment switch signal
Abnormality in engine water temperature (low- temperature) sensor system
‡
‡
TROUBLESHOOTING
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡ ‡‡‡
E11 E11 E11 E11

Abnormality in common rail fuel pressure sensor system
Abnormality in common rail fuel pressure
‡‡ ‡
‡‡ ‡
‡‡ ‡
‡
‡
‡
Abnormality in controller
‡ ‡‡‡ ‡ ‡‡ ‡
‡ ‡‡‡ ‡ ‡‡ ‡
‡ ‡‡‡ ‡ ‡‡ ‡
‡ ‡‡‡ ‡ ‡‡ ‡
‡ ‡‡‡ ‡ ‡‡ ‡
E15 — E0E E10 E15 — E15 E10 E10 E10 E10 E11 E11 E10 E11 E10 E11 E10 E10 E10 E10 E10 E10 E10 E10 E10
E11 E11 E11 E11 E11 E11 E11 E11 E11

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
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
Does starting motor turn?
is displayed
See engine volume

See engine volume
See engine volume
See engine volume
See engine volume
See engine volume
See engine volume
See engine volume
See engine volume
See engine volume
See engine volume
See engine volume
See engine volume
when no service code
AND ENGINE RELATED PARTS
JUDGEMENT TABLE FOR ENGINE CONTROLLER
20-261
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
20-262 PC750, 800-6

TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
PC750, 800-6 20-263

TROUBLESHOOTING E-1
E-1 [E91b] (Abnormality in engine speed Ne sensor system) is

displayed
Cause Remedy
1
• Turn starting switch Is resistance between NE (male) NO Defective engine speed Ne
OFF. (1) and (2), between (1) (2) and sensor Replace
• Disconnect NE. ground as shown in Table 1?
YES
Defective contact or
2
disconnection in wiring
• Turn starting switch Is resistance between E11 NO
OFF. harness between E11 (female) Repair or
(female) (5) and (12) 85 – 210 replace
• Disconnect E11. Ω? (5) and NE (female) (2) or
between E11 (female) (12) and
NE (female) (1)
YES
3 Short circuit with ground in

• Turn starting switch Is resistance between E11 NO wiring harness between E11 Repair or
OFF. (female) (5) (12) and ground (female) (5) and NE (female) replace
• Disconnect E11 and NE. more than 1 MΩ? (2) or between E11 (female)
(12) and NE (female) (1)
YES
Table 1
NE Resistance
(male) value
Between (1) and (2) 85 – 210 Ω
Between (1) (2) and ground Min. 1 MΩ
E-1 Related electrical circuit diagram
20-264 PC750, 800-6

TROUBLESHOOTING E-2
E-2 [E91C] (Abnormality in engine G rotation sensor system) is

displayed
Cause Remedy
1
• Turn starting switch Is resistance between G (male) NO Defective engine G rotation
OFF. (1) and (2), between (1) (2) and sensor Replace
• Disconnect G. ground as shown in Table 1?
YES
2
OFF. harness between E12 (female) Repair or
(female) (1) and (9) 1 k – 2 kΩ? (1) and G (female) (2) or replace
• Disconnect E12.
G (female) (1)
YES

OFF. (female) (1) (9) and ground (female) (1) and G (female) (2) replace
• Disconnect E12 and G. more than 1 MΩ? or between E12 (female) (9)
and G (female) (1)
YES
Table 1
G Resistance
(male) value
Between (1) and (2) 1 k – 2 kΩ
PC750, 800-6 20-265

TROUBLESHOOTING E-3
E-3 [E920] (Abnormality in model selection system) is displayed
Cause Remedy
1
• Turn starting switch Is resistance between E09 NO Defective model selection
OFF. (female) (1) (2) (3) and (8) as connector Replace
• Disconnect E09. shown in Table 1?
YES
2
OFF. (female) (13) (14) and (8) (19) harness between E14 (female) Repair or
• Disconnect E14. less than 1 Ω? (13) and E09 (male) (1) or replace
E09 (male) (2)
YES

OFF. (female) (15) and ground more (female) (15) and E09 (male) replace
• Disconnect E14 and E09. than 1 MΩ?
(3)
YES
Table 1
E09 Resistance
(male) value
Between (1) and (8) Max. 1 Ω
Between (2) and (8) Max. 1 Ω
Between (3) and (8) Min. 1 MΩ
20-266 PC750, 800-6

TROUBLESHOOTING E-3, E-4
Table 1 Display of monitoring code

Display of model code Display of model selection signal input status
Monitoring code 03 Monitoring code 85
fl The diagram shows monitoring code 02.

fl Check the display of the bit pattern marked with the arrow ().
Table 2 Voltage of wiring harness
E14 Between (13) Between (14) Between (15)

and chassis and chassis and chassis
Voltage Max. 1 V Max. 1 V 20 – 30 V
E-4 [E922] (Engine overrun) is displayed
Cause Remedy
1
Is another error code NO
displayed at same time? Go to
trouble-
YES shooting
— for service
code
displayed
2
Was machine used in a way NO Check
that would cause engine to cause of
overrun? problem
YES and repair
— damage to
engine
Go to
3 trouble-
Can engine speed be read NO shooting
• Start engine. — for service
correctly?
codes
[E91b],
YES [E91C]
PC750, 800-6 20-267

TROUBLESHOOTING E-5
E-5 [E924] (Drop in engine oil pressure) is displayed
Cause Remedy
1 Check
• See TESTING AND NO cause of
Is engine oil pressure normal? Drop in engine oil pressure
ADJUSTING. problem
and repair
YES damage to
2 engine
• Insert T-adapter to Is voltage between E14 (5) and NO
E14.
• Engine at low idling.
ground 20 – 30 V?
YES
3
• Turn starting switch
Is resistance between E14 NO Short circuit with ground in Repair or
OFF.
(female) (5) and ground more wiring harness between E14
than 1 MΩ? replace
PSL. (female) (5) and PSL
YES Defective engine oil low- Replace
pressure switch
• Insert T-adapter to E14. 4

• Run engine at mid- Is voltage between E14 (6) and NO
range speed (1300 rpm ground 20 – 30 V?
or more)
YES
• Turn starting switch 5

OFF. Is resistance between E14 NO Short circuit with ground in
(female) (6) and ground more Repair or
• Disconnect E14 and wiring harness between E14 replace
PSH. than 1 MΩ? (female) (6) and PSH
YES
Defective engine oil high- Replace
pressure switch
20-268 PC750, 800-6

TROUBLESHOOTING E-6
E-6 [E931] (Abnormality in fuel control dial sensor system) is

displayed
Cause Remedy
1
E06.
• Turn starting switch ON. (3) 4.6 – 5.4 V?
YES
2
• Insert T-adapter to
E11. Is voltage between E11 (4) and NO
Defective contact, disconnection,
YES or short circuit with ground in Repair or
wiring harness between E11 replace
(female) (4) and E06 (female) (1)
or E11 (female) (11) and E06
3 (female) (3)
• Turn starting switch Is resistance between E06 (male) (1) and
OFF. (3), between (2) and (3), and between (1)
NO
Defective fuel control dial Replace
• Disconnect E06. (2) and ground as shown in Table 1?
YES
4 Defective contact, disconnection,

• Turn starting switch Is resistance between E11 (female) (4) and NO or short circuit with ground in
OFF. (11), between (6) and (11), and between
Repair or
• Disconnect E11. wiring harness between E11 replace
(4) (6) and ground as shown in Table 2?
(female) (6) and E06 (female) (2)
YES
Table 1 Table 2
E06 Resistance E11 Resistance
(male) value (male) value
Between (1) and (3) 4.0 k – 6.0 kΩ Between (4) and (11) 4.0 k – 6.0 kΩ
Between (2) and (3) 0.24 – 7.0 kΩ Between (6) and (11) 0.24 – 7.0 kΩ
Between (1) (2) and ground Min. 1 MΩ Between (4) (6) and ground Min. 1 MΩ
PC750, 800-6 20-269

TROUBLESHOOTING E-7
E-7 [E934] (Abnormality in engine water high-temperature sensor

system) is displayed
Cause Remedy
OFF. Is resistance between TWH NO Defective engine water high-
• Disconnect TWH. (male) (1) and (2), between (1) Replace
and ground as shown in Table 1? temperature sensor
• Water temperature: 10
– 100°C
YES
• Turn starting switch 2 disconnection in wiring
OFF. Is resistance between E12 NO harness between E12 (female) Repair or
• Disconnect E12. (female) (4) and (10) 90 k – 3.5 (4) and TWH (female) (1) or replace
• Water temperature: 10 kΩ?
– 100°C between E12 (female) (10) and
TWH (female) (2)
YES

OFF.
Is resistance between E12 NO wiring harness between E12 Repair or
(female) (4) and ground more
than 1 MΩ? (female) (4) and TWH (female) replace
TWH. (1)
YES
Table 1
TWH Resistance
(male) value
Between (1) and (2) 90 k – 3.5 kΩ
Between (1) and ground Min. 1 MΩ
20-270 PC750, 800-6

TROUBLESHOOTING E-8
E-8 [E936] (Abnormality in engine oil pressure switch system) is

displayed
Cause Remedy
1
E14. ground as shown in Table 1?
YES
2
Is resistance between PSL NO Defective engine oil low-
• Disconnect PSL. (switch end) and ground as Replace
shown in Table 2? pressure switch
YES Defective contact,
Repair or
disconnection, or short circuit
replace
with ground in wiring harness
3 PSL
E14. ground as shown in Table 3?
YES
4
Is resistance between PSH NO Defective engine oil high-
• Disconnect PSH. (switch end) and ground as Replace
shown in Table 4? pressure switch
YES Defective contact or

disconnection in wiring Repair or
harness between E14 (female) replace
(5) and PSH
Table 1 Table 2
E14 Resistance
Engine Voltage PSL Engine
(male) value
Between (5) and When stopped Max. 1 V Between PSL (switch) When stopped Max. 1 Ω
ground At 600 rpm or more 20 – 30 V and ground At 600 rpm or more Min. 1 MΩ
Table 3 Table 4
Resistance Engine Resistance
E14 Engine PSH
value value
Between (6) and When stopped Max. 1 V Between PSH (switch) When stopped Max. 1 Ω
ground At 1300 rpm or more 20 – 30 V and ground At 1300 rpm or more Min. 1 MΩ
PC750, 800-6 20-271

TROUBLESHOOTING E-8
20-272 PC750, 800-6

TROUBLESHOOTING E-9
E-9 [E93C] (Abnormality in boost pressure sensor system) is displayed
Cause Remedy
1
• Connect T-adapter to Is voltage between E12 (2) and NO
E12.
(10) 4.6 – 5.4 V?
YES
Defective contact,
2 disconnection, or short circuit
• Disconnect PIM.
Is voltage between PIM NO between E12 (female) (2) and Repair or
ON. (female) (1) and (3) 4.6 – 5.4 V? PIM (female) (1) or E12 (female) replace
(10) and PIM (female) (3)
YES
Defective boost pressure Replace
sensor
3
E11 and E12.
• Turn starting switch ON. E12 (10) 0.3 – 4.7 V?
YES
Defective contact,
4
• Disconnect E11 and Is resistance between E11 (female) (3) and NO disconnection, or short circuit
PIM. PIM (female) (2), and between E11 (female) with ground in wiring harness Repair or
• Turn starting switch ON. (3) and ground as shown in Table 1? between E11 (female) (3) and replace
PIM (female) (2)
YES
Defective boost pressure
Replace
sensor
Table 1
E11, PIM Resistance
(female) value
Between E11 (3) and PIM (2) Max. 1 Ω
Between E11 (3) and ground Min. 1 MΩ
PC750, 800-6 20-273

TROUBLESHOOTING E-10
E-10 [E93d] (Abnormality in fuel temperature sensor system) is

displayed
Cause Remedy
OFF. Is resistance between THL (male) NO Defective fuel temperature
• Disconnect THL. (1) and (2), between (1) and Replace
ground as shown in Table 1? sensor
• Fuel temperature: 10 –
100°C
YES
• Turn starting switch 2 disconnection in wiring
OFF. Is resistance between E12 NO harness between E12 (female) Repair or
• Disconnect E12. (female) (11) and (10) 9 k – 0.3 (11) and THL (female) (1) or replace
• Fuel temperature: 10 – kΩ?
100°C E12 (female) (10) and THL
(female) (2)
YES

OFF.
(female) (11) and ground more
than 1 MΩ? (female) (11) and THL (female) replace
THL. (1)
YES
Table 1
THL Resistance
(male) value
Between (1) and (2) 9 k – 0.3 kΩ
20-274 PC750, 800-6

TROUBLESHOOTING E-11, E-12
E-11 [E954] (Short circuit in starting switch C system) is displayed
Cause Remedy
1
E14.
• Turn starting switch ON. ground less than 1 V?
YES
2
• Disconnect starting Is voltage between starting NO
switch terminal C. switch terminal C and ground Defective starting switch Replace
• Turn starting switch ON. less than 1 V?
YES Short circuit with power

source in wiring harness Repair or
between E14 (female) (2) and replace
starting switch terminal C
E-12 [E955] (Abnormality in network system) is displayed
fl Carry out troubleshooting for N Mode.
PC750, 800-6 20-275

E-13 [E956] (Power source system abnormality 1) is displayed
fl Before carrying out troubleshooting, check that circuit breaker 8 has not shut off the circuit. (If the
breaker has shut off the circuit, there has probably been a surge of current caused by a short
circuit with the ground, so check the circuits related to circuit breaker 8.)
Cause Remedy
1
• Insert T-adapter to E17. Is voltage between E17 (6) (14) NO
• Turn starting switch ON. and (5) (13) 20 – 30 V?
YES
2
• Turn starting switch Is resistance between R24 NO
OFF. Defective power source relay
(male) (1) and (2) 200 – 900 Ω? (coil end) Replace
• Disconnect R24.
YES
Defective contact,
• Insert T-adapter to R24. Is voltage between R24 (1) and NO with ground in wiring harness Repair or
OFF.
ground 20 – 30 V? between starting switch replace
terminal ACC and R24
YES (female) (1)
4 Defective contact or
• Turn starting switch Is resistance between R24 NO disconnection in wiring Repair or
OFF. (female) (2) and ground less
• Disconnect R24. than 1 Ω? harness between R24 (female) replace
(2) and ground
YES
Defective contact,
• Insert T-adapter to R24. Is voltage between R24 (3) and NO with ground in wiring harness Repair or
• Turn starting switch ON. ground 20 – 30V? between battery relay replace
terminal B – circuit breaker 8 –
YES R24 (female) (3)
6
• Insert T-adapter to R24. Is voltage between R24 (5) and NO Defective power source relay
• Turn starting switch Replace
OFF. ground 20 – 30 V? (contact end)
Defective contact,
YES disconnection, or short circuit Repair or
with ground in wiring harness replace
between E17 (female) (6) (14)
and R24 (female) (5)
20-276 PC750, 800-6

PC750, 800-6 20-277

TROUBLESHOOTING E-14, 15
E-14 [E957] (Power source system abnormality 2) is displayed

Cause Remedy
1
• Insert T-adapter to E17. Is voltage between E17 (6) (14) NO
OFF.
and (5) (13) less than 8 V?
YES
2
• Disconnect R24.
• Insert T-adapter to E17. Is voltage between E17 (6) (14) NO Defective power source relay
• Turn starting switch and (5) (13) less than 8 V? (contact end) Replace
OFF.
YES Short circuit with power
between E17 (female) (6) (14) replace
and R24 (female) (5)
E-15 [E95A] (Abnormality in fuel injection amount adjustment switch

signal) is displayed
Cause Remedy
1
Are both fuel injection amount NO
adjustment switches 1 and 2 Defective engine controller Replace
set to [F]?
YES Defective fuel injection Adjust

amount adjustment switch again
setting
20-278 PC750, 800-6

E-16 [E96A] (Abnormality in engine water low-temperature sensor

system) is displayed
Cause Remedy
OFF. Is resistance between TWL NO Defective engine water low-
• Disconnect TWL. (male) (1) and (2), between (1) temperature sensor Replace
• Water temperature: 10 and ground as shown in Table 1?
– 100°C
YES
OFF. Is resistance between E12 NO
(female) (3) and (10) 9 k – 0.3 harness between E12 (female) Repair or
• Disconnect E12. replace
• Water temperature: 10 kΩ? (3) and TWL (female) (1) or
– 100°C between E12 (female) (10) and
TWL (female) (2)
YES

OFF.
(female) (3) and ground more (female) (3) and TWL (female) replace
• Disconnect E12 and than 1 MΩ?
TWL. (1)
YES
Table 1
TWL Resistance
(male) value
Between (1) and (2) 9 k – 0.3 kΩ
PC750, 800-6 20-279

E-17 [E970] (Excess current in fuel supply pump PCV1 system) is

displayed
Cause Remedy
1
• Turn starting switch Is resistance between PCV1 NO Defective fuel supply pump
OFF. (male) (1) and (2), between (1) (2) Replace
• Disconnect PCV1. and ground as shown in Table 1? PCV1
YES
Short circuit with ground, or

2 short circuit with power source
• Turn starting switch Is resistance between E17 NO in wiring harness between E17 Repair or
OFF. (female) (10) and (11), (10) (11) (female) (10) and PCV1 (female) replace
• Disconnect E17. and ground as shown in Table 2?
(1) or between E17 (female) (11)
and PCV1 (female) (2)
YES
Table 1 Table 2
PCV1 Resistance E17 Resistance
Between (1) and (2) 2.3 – 5.3 Ω Between (10) and (11) 2.3 – 5.3 Ω
20-280 PC750, 800-6

E-18 [E971] (Excess current in fuel supply pump PCV2 system) is

displayed
Cause Remedy
1
OFF. (male) (1) and (2), between (1) (2) Replace
• Disconnect PCV2. and ground as shown in Table 1? PCV2
YES
Short circuit with ground, or

2 short circuit with power source
• Turn starting switch Is resistance between E17 NO in wiring harness between E17 Repair or
OFF. (female) (4) and (12), (4) (12) and (female) (4) and PCV2 (female) replace
• Disconnect E17. ground as shown in Table 2?
(1) or between E17 (female)
(12) and PCV2 (female) (2)
YES
Table 1 Table 2
PCV2 Resistance E17 Resistance
Between (1) and (2) 2.3 – 5.3 Ω Between (4) and (12) 2.3 – 5.3 Ω
PC750, 800-6 20-281

E-19 [E974] (Disconnection in fuel supply pump PCV1 system) is

displayed
Cause Remedy
1
OFF. Replace
• Disconnect PCV1. (male) (1) and (2) 2.3 – 5.3 Ω? PCV1
YES
Defective contact,
• Turn starting switch Is resistance between E17 NO with ground in wiring harness Repair or
OFF. (female) (10) and (11), (11) and between E17 (female) (10) and
• Disconnect E17. ground as shown in Table 1? PCV1 (female) (1) or between replace
E17 (female) (11) and PCV1
YES (female) (2)
Table 1
E17 Resistance
(male) value
Between (10) and (11) 2.3 – 5.3 Ω
20-282 PC750, 800-6

E-20 [E975] (Disconnection in fuel supply pump PCV2 system) is

displayed
Cause Remedy
1
OFF. Replace
• Disconnect PCV2. (male) (1) and (2) 2.3 – 5.3 Ω? PCV2
YES
Defective contact,
• Turn starting switch Is resistance between E17 NO with ground in wiring harness Repair or
OFF. (female) (4) and (12), (12) and between E17 (female) (4) and
• Disconnect E17. ground as shown in Table 1? PCV2 (female) (1) or between replace
E17 (female) (12) and PCV2
YES (female) (2)
Table 1
E17 Resistance
(male) value
Between (4) and (12) 2.3 – 5.3 Ω
PC750, 800-6 20-283

E-21 [E977] (Abnormality in common rail fuel pressure sensor system)

is displayed
Cause Remedy
1
E12.
YES
Defective contact,
2 between E12 (female) (2) and
• Disconnect PFUEL. Is voltage between PFUEL NO PFUEL (female) (3) or between Repair or
• Turn starting switch ON. (female) (1) and (3) 4.6 – 5.4 V? E12 (female) (10) and PFUEL replace
(female) (1)
YES
Defective common rail fuel
Replace
pressure sensor
3
E11 and E12.
• Turn starting switch ON. E12 (10) 0.3 – 4.7 V?
YES
4 Defective contact,
• Disconnect E11 and Is resistance between E11 (female) (1) and disconnection, or short circuit
NO
PFUEL. PFUEL (female) (2), and between E11 with ground in wiring harness Repair or
• Turn starting switch ON. (female) (1) and ground as shown in Table 1? between E11 (female) (1) and replace
PFUEL (female) (2)
YES
Defective common rail fuel
Replace
pressure sensor
Table 1
E11, PFUEL Resistance
(female) value
Between E11 (1) and PFUEL (2) Max. 1 Ω
Between E11 (1) and ground Min. 1 MΩ
20-284 PC750, 800-6

E-22 [E979] (Common rail fuel high pressure abnormality 1) is

displayed
[E97A] (Common rail fuel high pressure abnormality 2) is
displayed
Cause Remedy
1
trouble-
YES shooting
— for service
code
displayed
2
Is fuel being used suitable for NO
ambient temperature? Unsuitable fuel being used Change
YES
3
• Loosen joint of fuel When priming pump is NO
supply pump overflow operated, does fuel leak out
valve. from connection of joint?
YES
4 Go to
• Disassemble fuel In overflow valve, is spring NO Trouble-
supply pump overflow broken, seat worn, or ball — shooting
valve. stuck?
No. 7
YES
Defective overflow valve Replace
5
• Loosen joint of When engine is started, does NO
common rail pressure fuel leak out from connection
limiter. of joint?
YES
6
When troubleshooting for error NO
code [E977] is carried out, does any Defective pressure limiter Replace
problem occur in electrical system?
YES Defective electrical system of Repair or
common rail fuel pressure replace
sensor
7
NO Defective mechanical system
Is overflow pipe clogged? of common rail fuel pressure Replace
sensor
YES
Clean or
Clogged overflow pipe
replace
PC750, 800-6 20-285

E-23 [E97b] (Fuel supply pump non-force feed 1) is displayed

[E97C] (Fuel supply pump non-force feed 2) is displayed
Cause Remedy
1
trouble-
YES shooting
— for service
code
displayed
2
Does fuel being used match NO
ambient temperature? Unsuitable fuel being used Change
YES
• Check visually with

3
engine stopped, then Is there any leakage of fuel from fuel pump, NO
check visually with high- pressure primary piping, common rail,
engine at low idling. or high-pressure secondary piping?
YES Fuel leakage in high-pressure Repair or
circuit replace
4
Is filter or strainer clogged? NO
(Note 1)
YES Clean or
Clogged filter, strainer
replace
5
• Measure fuel pressure Is fuel low-pressure circuit
(see TESTING AND NO Defective equipment in low- Repair or
pressure 0.15 – 0.3 MPa {1.5 –
ADJUSTING). 3 kg/cm2}? pressure circuit (See Note 2) replace
• Engine at high idling.
YES
6
• Disconnect outlet
piping of common rail Is drain amount from pressure NO
Defective pressure limiter Replace
pressure limiter. limiter less than 10 cc/min?
• Start engine.
YES
7
• Disconnect PVC Does engine stop when PCV connector NO
connector on one side. is disconnected from one side of fuel
• Start engine. pump and engine is run on one lung?
YES
8
• Disconnect hose at
portion collecting spill Is spill flow from injector NO
from injector. Defective fuel injector Replace
normal? (See Note 3)
• Start engine.
YES Defective common rail fuel
Replace
pressure sensor
9
Carry out troubleshooting for service NO
codes [E970], [E971], [E974], [E975]. Does Defective fuel supply pump Replace
any problem occur with electrical system?
YES Defective electrical system of Repair or
fuel supply pump PCV replace
20-286 PC750, 800-6

Note 1: Inspect, clean, and replace the filter and strainer as follows.
1) Gauze filter
Disassemble and inspect; clean if clogged.
2) Strainer on upstream side of gauze filter
If the gauze filter is clogged, clean the upstream strainer also.
3) Fuel filter
If the problem is not removed by Steps 1) and 2) above, replace the fuel strainer.
Note 2: If the equipment in the low-pressure circuit is defective, inspect the following points.
1) Remaining amount of fuel
2) Stuck, worn feed pump
3) Leakage, clogged low-pressure fuel piping
4) Defective actuation of bypass valve, incorrect assembly with other parts (See Fig. 1)
5) Fuel entering oil pan (fuel leakage inside head cover)
Fig. 1 Installation position of overflow valve 1, bypass valve 2, fuel inlet port joint (with gauze filter)
3
PC750, 800-6 20-287

TROUBLESHOOTING E-23, E-24, E-25
Note 3: Method of measuring amount of fuel spill Limits for fuel spill amount
flow (total for 6 cylinders)
¤ The fuel in the spill line is at high tempera- Stall speed (rpm) Spill limit (cc/min)
ture (up to 90°C), so be careful not to burn
yourself during the operation. 1,600 960
1) Disconnect the hose connected to the spill 1,700 1,020
tube return collection portion (rear of en-
gine). 1.800 1,080
2) Connect another hose to the tip of the spill 1,900 1,140
tube, and collect the spill fuel in a container.
3) Start the engine, stall the engine at each 2,000 1,200
speed, and measure the spill fuel amount
for 1 minute.
E-24 [E97d] (Abnormality in common rail fuel pressure) is displayed
fl Go to Troubleshooting of error codes [E979] and [E97A].
E-25 [E980] (Defective engine controller) is displayed
Cause Remedy
• Turn starting switch Is resistance between E17 NO Repair or
OFF.
(female) (5) (13) and ground
• Disconnect E17. less than 1 Ω? harness between E17 (female) replace
(5) (13) and ground
YES
20-288 PC750, 800-6

E-26 [E981] (Disconnection in No. 1 fuel injector system) is displayed
¤ A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of
electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling engine
controller high-voltage circuit.
Cause Remedy
1
• Turn starting switch Is resistance between CN1 NO
OFF. Defective No. 1 fuel injector Replace
• Disconnect CN1. (male) (1) and (2) 0.4 – 1.1 Ω?
YES
2 disconnection in wiring
• Turn starting switch Is resistance between E16 NO harness between E16 (female) Repair or
OFF.
• Disconnect E16. (female) (7) and (8) 0.4 – 1.1 Ω? (7) and CN1 (female) (1) or replace
YES CN1 (female) (2)
PC750, 800-6 20-289

Cause Remedy
1
YES
OFF.
20-290 PC750, 800-6

Cause Remedy
1
YES
OFF.
PC750, 800-6 20-291

controlle-high voltage circuit.
Cause Remedy
1
YES
OFF.
20-292 PC750, 800-6

Cause Remedy
1
YES
OFF.
PC750, 800-6 20-293

Cause Remedy
1
YES
OFF.
20-294 PC750, 800-6

E-32 [E98A] (Short circuit in No. 1, No. 2, No. 3 fuel injector system) is
displayed
a) Determining system with problem
Cause Remedy
1 Go to
• Turn starting switch Is resistance between E16 (female) NO Abnormality in No. 1 fuel trouble-
OFF. (7) and (8), between (7) (8) and
• Disconnect E16. ground as shown in Table 1? injector system shooting
procedure b)
YES
2 Go to
• Turn starting switch Is resistance between E16 (female) NO
OFF.
Abnormality in No. 2 fuel trouble-
(4) and (10), and between (4) (10)
• Disconnect E16. and ground as shown in Table 1? injector system shooting
procedure c)
YES
3 Go to
OFF. (3) and (9), and between (3) (9) and injector system shooting
procedure d)
YES
• Turn starting switch Is resistance between E17 NO disconnection in wiring Repair or
OFF. (female) (5) (13) and ground harness between E17 (female) replace
• Disconnect E17. less than 1 Ω?
(5) (13) and ground
YES
Table 1
E16 E16 E16 Resistance
(female) (female) (female) value
Between (7) and (8) Between (4) and (10) Between (3) and (9) 0.4 – 1.1 Ω
Between (7) (8) and ground Between (4) (10) and ground Between (3) (9) and ground Min. 1 MΩ
PC750, 800-6 20-295

b) Troubleshooting No. 1 fuel injector system
Cause Remedy
1
• Turn starting switch Is resistance between CN1 (male) NO
OFF. (1) and (2), and between (1) (2) and Defective No. 1 fuel injector Replace
• Disconnect CN1. ground as shown in Table 2?
Short circuit with ground or
YES short circuit with power
CN1 (female) (1) or between
Table 2 E16 (female) (8) and CN1
(female) (2)
CN1 Resistance
(female) value
Between (1) and (2) 0.4 – 1.1 Ω
c) Troubleshooting No. 2 fuel injector system
Cause Remedy
1
(female) (2)
CN2 Resistance
(female) value
Between (1) and (2) 0.4 – 1.1 Ω
d) Troubleshooting No. 3 fuel injector system
Cause Remedy
1
(female) (2)
CN3 Resistance
(female) value
Between (1) and (2) 0.4 – 1.1 Ω
20-296 PC750, 800-6

E-32 a) b) Related electrical circuit diagram
E-32 a) c) Related electrical circuit diagram
PC750, 800-6 20-297

E-32 a) d) Related electrical circuit diagram
20-298 PC750, 800-6

E-33 [E98b] (Short circuit in No. 3, No. 4, No. 5 fuel injector system) is
displayed
controller high voltage circuit.
a) Determining location of problem
Cause Remedy
1 Go to
OFF. (3) and (9), and between (3) (9) and
procedure b)
YES
2 Go to
• Turn starting switch Is resistance between E17 (female) NO
OFF.
Abnormality in No. 5 fuel trouble-
(1) and (7), and between (1) (7) and
procedure c)
YES
3 Go to
OFF. (2) and (8), and between (2) (8) and injector system shooting
procedure d)
YES
• Turn starting switch Is resistance between E17 NO disconnection in wiring Repair or
OFF. (female) (5) (13) and ground harness between E17 (female) replace
• Disconnect E17. less than 1 Ω?
(5) (13) and ground
YES
Table 1
E17 E17 E17 Resistance
(female) (female) (female) value
Between (3) and (9) Between (1) and (7) Between (2) and (8) 0.4 – 1.1 Ω
Between (3) (9) and ground Between (1) (7) and ground Between (2) (8) and ground Min. 1 MΩ
PC750, 800-6 20-299

b) Troubleshooting No. 4 fuel injector system
Cause Remedy
1
(female) (2)
CN4 Resistance
(female) value
Between (1) and (2) 0.4 – 1.1 Ω
c) Troubleshooting No. 5 fuel injector system
Cause Remedy
1
E17 (female) (7) and CN5
Table 3 (female) (2)
CN5 Resistance
(female) value
Between (1) and (2) 0.4 – 1.1 Ω
d) Troubleshooting No. 6 fuel injector system
Cause Remedy
1
(female) (2)
CN6 Resistance
(female) value
Between (1) and (2) 0.4 – 1.1 Ω
20-300 PC750, 800-6

E-33 a) b) Related electrical circuit diagram
E-33 a) c) Related electrical circuit diagram
PC750, 800-6 20-301

E-33 a) d) Related electrical circuit diagram
20-302 PC750, 800-6

TROUBLESHOOTING OF
PUMP CONTROLLER SYSTEM
(C MODE)
Points to remember when troubleshooting controller system .........................................................20-402

Action taken by controller when abnormality occurs and problems on machine ..........................20-404
Judgement table for pump controller and hydraulic related parts ..................................................20-412
Electrical circuit diagram for C mode system .....................................................................................20-414
Troubleshooting flow charts for each failure mode ...........................................................................20-416
C- 1 Abnormality in controller power source system (controller LED is OFF) .........................20-416
C- 2 [E232] Short circuit in pump TVC solenoid system is displayed .......................................20-417
C- 3 [E233] Disconnection in pump TVC solenoid system is displayed ....................................20-419
C- 4 [E203] Short circuit in swing holding brake solenoid system is displayed ...................... 20-421
C- 5 [E213] Disconnection in swing holding brake solenoid system is displayed ...................20-423
C- 6 [E201] Short circuit in CO cancel solenoid system is displayed ........................................20-425
C- 7 [E211] Disconnection in CO cancel solenoid system is displayed .....................................20-426
C- 8 [E202] Short circuit in straight-travel solenoid system is displayed .................................20-427
C- 9 [E212] Disconnection in straight-travel solenoid system is displayed ..............................20-428
C-10 [E204] Short circuit in 2-stage relief solenoid system is displayed ...................................20-429
C-11 [E214] Disconnection in 2-stage relief solenoid system is displayed ................................20-430
C-12 [E205] Short circuit in swing priority selector solenoid system is displayed ..................20-431
C-13 [E211] Disconnection in swing priority selector solenoid system isdisplayed .................20-432
C-14 [E206] Short circuit in travel speed solenoid system is displayed ....................................20-433
C-15 [E216] Disconnection in travel speed solenoid system is displayed .................................20-434
C-16 [E217] Model selection input error is displayed ..................................................................20-435
C-17 [E227] Abnormality in engine speed sensor system is displayed .....................................20-437
C-18 Abnormality in machine push-up solenoid system (no service code displayed) ............20-438
C-19 Abnormality in shockless boom solenoid system (no service code displayed) .............. 20-440
C-20 [E207] Short circuit in flash light relay drive system is displayed ....................................20-443
C-21 Flash light relay does not work .............................................................................................20-444
C-22 [E231] Abnormality (short circuit) in power source holding relay output system for step
light is displayed ......................................................................................................................20-445
C-23 Step light switch does not work ............................................................................................20-446
C-24 [E302] Short circuit in step light relay drive system is displayed .....................................20-447
C-25 [303] Disconnection in step light relay drive system is displayed ....................................20-448
C-26 Step light does not light up ...................................................................................................20-449
C-27 [E228] Abnormality in auto-deceleration output system is displayed ...............................20-450
PC750, 800-6 20-401

TROUBLESHOOTING CONTROLLER SYSTEM

CONTROLLER SYSTEM
1. Points to remember if abnormality returns to normal by itself
In the following cases, there is a high probability that the same problem will occur again, so it is
desirable to follow up this problem carefully.
1) If any abnormality returns to normal by itself, or
2) 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 when carrying out troubleshooting of the
failure, and the service code is no longer displayed, or if the monitor display returns to normal.
3) After completing troubleshooting, always erase the service code from memory.
2. Service code memory retention function

When displaying the service code in memory and carrying out troubleshooting, note down the
content of the display, then erase the display. After trying to re-enact the problem, carry out
troubleshooting according to the service code that is displayed.
(There are cases where mistaken operation or abnormalities that occur when the connector is
disconnected are recorded by the memory retention function. Erasing the data in this way saves
any wasted work.)
20-402 PC750, 800-6


User Service
code code
1. Short circuit with ground, short circuit inside pump TVC solenoid
2. Short circuit with power source, short circuit with ground in wiring
harness between controller C02 (8) and TVC solenoid C13 (1) ((+)
Short circuit in TVC end)
E232
solenoid system 3. Short circuit with power source in wiring harness between control-
ler C02 (18) and TVC solenoid C13 (2) ((–) end)
1. Disconnection, defective contact inside pump TVC solenoid

2. Disconnection, defective contact in wiring harness between con-
E02
troller C02 (8) and TVC solenoid C13 (1) ((+) end)
3. Disconnection, defective contact, short circuit with ground in wir-
ing harness between controller C02 (18) and TVC solenoid C13 (2)
((–) end)
E233 Disconnection in TVC 4. Defective pump controller
solenoid system
1. Short circuit with ground, short circuit inside swing holding brake
solenoid
2. Short circuit with ground in wiring harness between controller C01
Short circuit in (3) and solenoid V04 (2) ((+) end)
E203 swing holding brake 3. Defective pump controller
solenoid system
E03 1. Disconnection, defective contact inside swing holding brake sole-

noid
2. Disconnection, defective contact, short circuit with power source in
Disconnection in wiring harness between controller C01 (3) and solenoid V04 (2) ((+)
E213 swing holding brake end)
solenoid system 3. Disconnection, defective contact in wiring harness between sole-
noid V04 (1) and chassis ground ((–) end)
1. Short circuit with ground, short circuit inside CO cancel solenoid

Short circuit in CO 2. Short circuit with ground in wiring harness between controller C01
— E201 cancel solenoid (8) and solenoid V07 (2) ((+) end)
system 3. Defective pump controller
1. Disconnection, defective contact inside CO cancel solenoid

Disconnection in CO wiring harness between controller C01 (8) and solenoid V07 (2) ((+)
— E211 cancel solenoid end)
system 3. Disconnection, defective contact in wiring harness between sole-
20-404 PC750, 800-6

1. Makes output to TVC solenoid 0. 1. No current flows to the TVC so-
2. Displays user code E02 on monitor lenoid. Therefore, when the load
panel. is large, there is a big drop in
· Resistance of solenoid: fl If the abnormality is restored by the the engine speed, which may
10 – 22 Ω vibration of the machine, the power result in the engine stalling.
source is reset to restore to the proper 2. The swing acceleration is poor
condition. (However, the service code
display does not go out.)
1. The current stops flowing to the TVC 1. In the case of 1, it is the same
solenoid, so no particular action is as E232.
taken. 2. In the case of 2, the current (min.
· Resistance of solenoid: 2. If there is a short circuit with the 1 A) continues to flow to the
10 – 22 Ω ground at the (–) end, the current (min. TVC solenoid, so the output of
· Current: 1000 mA 1 A) continues to flow to the TVC so- the TVC valve increases and the
(DH mode, auto-decelera- lenoid. overall speed becomes slower.
tion ON, levers at neu- 3. Displays user code E02 on the moni-
tral, fuel control dial at tor panel.
FULL) fl If the abnormality is restored by the
vibration of the machine, it resets au-
tomatically to restore to the proper
1. Makes output to solenoid 0.

2. Displays user code E03 on monitor
panel. When the swing is operated, the
· Resistance of solenoid: fl If the abnormality is restored by the motor brake is not released, so the
20 – 60 Ω vibration of the machine, the power upper structure does not swing.
source is reset to restore to the proper
1. The current stops flowing to the sole-

noid, so no particular action is taken.
2. Displays user code E03 on monitor
panel.
· Resistance of solenoid: fl If the abnormality is restored by the Same as display for E203
20 – 60 Ω vibration of the machine, it resets au-
1. Makes output to TVC solenoid 0.

fl If the abnormality is restored by the
· Resistance of solenoid: vibration of the machine, the power Lack of power in DH mode or heavy
20 – 60 Ω source is reset to restore to the proper lift

· Resistance of solenoid: vibration of the machine, it resets au- Same as display for E201
20 – 60 Ω tomatically to restore to the proper
PC750, 800-6 20-405

User Service
code code
1. Short circuit with ground, short circuit inside straight-travel sole-
Short circuit in noid
— E202 straight-travel 2. Short circuit with ground in wiring harness between controller C01
solenoid system (2) and solenoid V03 (2) ((+) end)
1. Disconnection, defective contact inside straight-travel solenoid

— E212 straight-travel end)
1. Short circuit with ground, short circuit inside 2-stage relief sole-
noid
Short circuit in 2-
— E204 stage relief solenoid
(10) and solenoid V05 (2) ((+) end)
system
1. Disconnection, defective contact inside 2-stage relief solenoid

Disconnection in 2- wiring harness between controller C01 (10) and solenoid V05 (2)
— E214 stage relief solenoid ((+) end)
system 3. Disconnection, defective contact in wiring harness between sole-
1. Short circuit with ground, short circuit inside swing priority selec-
Short circuit in tor solenoid
— E205 swing priority 2. Short circuit with ground in wiring harness between controller C01
selector solenoid (5) and solenoid V01 (2) ((+) end)
1. Disconnection, defective contact inside swing priority selector so-

Disconnection in lenoid
swing priority 2. Disconnection, defective contact, short circuit with power source in
— selector solenoid R wiring harness between controller C01 (5) and solenoid V01 (2) ((+)
E215 end)
pump pressure
sensor system 3. Disconnection, defective contact in wiring harness between sole-
20-406 PC750, 800-6

fl If the abnormality is restored by the In compound operations with
· Resistance of solenoid: vibration of the machine, the power bucket CURL, all speeds except
20 – 60 Ω source is reset to restore to the proper bucket CURL are slow


fl If the abnormality is restored by the Power does not increase in boom
· Resistance of solenoid: vibration of the machine, the power RAISE (operated independently) in
20 – 60 Ω source is reset to restore to the proper heavy lift mode

· Resistance of solenoid: fl If the abnormality is restored by the
20 – 60 Ω vibration of the machine, it resets au- Same as display for E204
1. Makes output to solenoid 0. When swing and boom RAISE are

fl If the abnormality is restored by the operated at the same time, there is
· Resistance of solenoid: vibration of the machine, the power no difference between swing speed
20 – 60 Ω source is reset to restore to the proper and amount of boom raise, regard-
condition. (However, the service code less of whether swing priority
display does not go out.) switch is ON or OFF

PC750, 800-6 20-407

User Service
code code
1. Short circuit with ground, short circuit inside travel speed solenoid
Short circuit in
— (9) and solenoid V06 (2) ((+) end)
E206 travel speed 3. Defective pump controller
solenoid system
1. Disconnection, defective contact inside travel speed solenoid

— E216 travel speed end)
1. Disconnection, defective contact, short circuit with ground in model

selection wiring harness C17(5) (6) (7) (13) (14)
— E217 Model selection
input error
1. Disconnection, defective contact, short circuit with ground inside

engine speed sensor
Abnormality in 2. Disconnection, defective contact, short circuit with ground in wir-
— E227 engine speed sensor ing harness between controller C16 (1) and speed sensor ENE (2)
system ((–) end), and between C16 (2) and ENE (1) (SIG end)
1. Disconnection, short circuit, short circuit with ground in network

wiring harness
2. Abnormality in pump controller
Network response 3. Abnormality in monitor panel
— E218
overtime error 4. Abnormality in engine controller
1. Short circuit, short circuit with ground inside flash light relay
Abnormality in flash 2. Short circuit with ground, short circuit with power source in wiring
— light relay drive harness between controller C01 (11) and flash light relay R16 (1)
E207
1. Failure in power source holding relay output for step light

Failure in power 2. Short circuit with power source in wiring harness between control-
— source holding relay ler C02 (6) and power source holding relay R25 (2) for step light
E231
output system for 3. Defective pump controller
step light
1. Short circuit, short circuit with ground inside flash light relay
2. Short circuit with ground, short circuit with power source in wiring
Short circuit in step harness between controller C01 (1) and step light R17 (1)
— E302 light relay drive 3. Defective pump controller
system
20-408 PC750, 800-6

fl If the abnormality is restored by the Even if the travel speed is switched,
· Resistance of solenoid: vibration of the machine, the power the travel speed does not change
20 – 60 Ω source is reset to restore to the proper (remains at Lo)

· Between C17 (7),(13) and Detects abnormality in input 1. Engine stalls, or

chassis: Max. 1 Ω 1. Retains data when starting switch is 2. Work equipment, swing, travel
· Between C17 (5),(6),(14) ON. speeds are all slow or lack
and chassis: Min. 1 MΩ 2. Functions as PC300 when non-set con- power
ditions are input.
1. Functions in the equivalent of G mode Operates about the same as G

· Resistance: 500 – 1000 Ω (speed rises) mode (emergency) (the power is
· Voltage (AC range) : lower)
0.5 – 3.0 V (engine started)
1. When communications are impossible 1. (1) Even when travel is oper-

with the monitor, control is carried ated, power does not in-
out with the following settings. crease
(1) Working mode: G (2) Auto-deceleration cannot be
(2) Travel speed: Lo canceled
(3) Auto-deceleration: ON (3) Travel speed does not in-
(4) Heavy lift: OFF crease
(others are as normal)
1. Makes output to solenoid 0. Flash light does not light up

When horn is ON, relay con- fl If the abnormality is restored by the
tacts repeatedly change ON/ vibration of the machine, it resets au-
OFF tomatically to restore to the proper
1. Makes output to solenoid 0. When key is OFF, step light does

When step light is ON, power fl If the abnormality is restored by the not light up
source holding relay contacts vibration of the machine, it resets au-
for step light come ON tomatically to restore to the proper
1. Makes output to solenoid 0. Flash light does not light up

When step light switch is ON, fl If the abnormality is restored by the
step light relay contacts come vibration of the machine, it resets au-
ON tomatically to restore to the proper
PC750, 800-6 20-409

User Service
code code
1. Defective contact or disconnection in wiring harness between in-
side flash light relay
Disconnection in 2. Defective contact, disconnection, short circuit with power source in
— E303 step light relay drive wiring harness between controller C01 (1) and step light R17 (1)
Abnormality in auto- 1. Disconnection, defective contact, short circuit with ground in wir-
deceleration output ing harness between pump controller C01 (4) and engine controller
— E228
system E14 (11)
20-410 PC750, 800-6

1. The current stops flowing to the re- Step light does not light up
lay, so no particular action is taken.
When step light switch is ON, fl If the abnormality is restored by the
step light relay contacts come vibration of the machine, it resets au-
ON tomatically to restore to the proper
1. Functions with signal from network No abnormality appears. (However,

Resistance between C01 (fe- (S-NET) circuit. if an abnormality occurs at the
male) (4) and E14 (female) same time in the network, the auto-
(11): Max. 1 Ω deceleration stops working.)
PC750, 800-6 20-411

JUDGEMENT TABLE FOR PUMP CONTROLLER AND
TROUBLESHOOTING HYDRAULIC RELATED PARTS

HYDRAULIC RELATED PARTS
Pump controller (E2:XX system)
Parts causing failure
Short circuit in swing holding brake solenoid system
Disconnection in straight-travel solenoid system

Disconnection in CO cancel 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
Failure mode User code LED E02 E03 —
Service code OFF 232 233 203 213 201 211 202 212
▲ ▲
All work equipment,
Speeds of all work equipment, swing, travel are slow or lack power
travel, swing
Engine speed drops or engine stalls o o o

No work equipment, travel, swing move
Abnormal noise generated (around pump)
Auto-deceleration does not work o
Boom is slow or lacks power o o
Arm is slow or lacks power o o
Bucket is slow or lacks power
Work equipment
o o
Boom does not move
Arm does not move
Bucket does not move
Excessive hydraulic drift
Excessive time lag
Excessive shock when stopping boom (shockless switch ON)
Machine push-up function does not work properly
Travel deviation is excessive during compound operations o o
Machine deviates naturally to one Direction of deviation is same in FORWARD and REVERSE
Travel system
side during travel operations Direction of deviation is different in FORWARD and REVERSE
Deviation is excessive when starting
Travel speed is slow o o
Travel speed does not switch or is faster (slower) than set speed o
Does not move (one side only)
Both left and right o o
Does not swing
One direction only
Swing speed is slow or Both left and right
swing acceleration is poor One direction only
Swing speed is slow or swing acceleration is poor during compound operations with arm or bucket
Swing system
When swing priority is ON, swing speed is slow or swing acceleration is poor during compound operations with boom RAISE
Excessive overrun when Both left and right
stopping swing One direction only
Excessive shock when stopping swing
Excessive abnormal noise when stopping swing
Excessive hydraulic drift of When swing holding brake is released
swing When swing holding brake is applied
Troubleshooting code when service code is displayed C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9
Troubleshooting code when there is abnormality in monitoring code check — — — — — — — — —
o This shows applicable item for service code
When heavy lift switch is ON and boom is operated independently (applicable item for service code)
9 This shows items to inspect with monitoring or machine monitor
▲ CO is canceled in DH mode
20-412 PC750, 800-6

TROUBLESHOOTING HYDRAULIC RELATED PARTS
fl If service code E218 (abnormality in network system) is displayed, go to troubleshooting for N mode.
Pump controller (E2:XX system) Check items in monitoring mode
Self-diagnostic display Oil pressure switches Solenoid drive condition
Disconnection in 2-stage relief solenoid system
Disconnection in swing priority solenoid system

Short circuit in travel speed solenoid system
Short circuit in 2-stage relief solenoid system
Disconnection in travel speed solenoid system
Abnormality in engine speed sensor system

Short circuit in swing priority 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
Bucket DUMP
Bucket CURL
2-stage relief
Travel speed
Boom RAISE
R.H. travel
L.H. travel
CO cancel
Arm OUT
Model code
Arm IN
Swing
1 2 3 4 5 6 1 2 5 3 1 2 3 4 5 6
— Bit pattern Monitoring code
204 214 205 215 206 216 217 227 20 21 23 02 10 13

‡ ‡ 9 9 9 H-1
‡ ‡ 9 9 H-2
H-3
H-4
9 9 9 9 9 9 9 9 9 H-5
9 9 9 9
9 9 9 H-6
9 9 9
H-7
H-8
H-9
9 C-19, H-10
9 C-18, H-11
9 9 9 9 9 9 9 9 9 9 H-12
H-13
H-14
9 9 9 H-15
o o H-16
H-17
9
H-18
9
H-19
H-20
o o H-21
H-22
H-23
H-24
H-25
9 9 9 9 9 9 9 9
C-10 C-11 C-12 C-13 C-14 C-15 C-16 C-17 — — — — — — — — — — — — — — — — — — — — —
— — — — — — — — F-1 F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-11 — — — — — — — — — — —
PC750, 800-6 20-413

TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM
20-414 PC750, 800-6

TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM
PC750, 800-6 20-415

TROUBLESHOOTING C-1
C-1 Abnormality in controller power source system (controller LED is

OFF)
fl Check that circuit breaker 5 is not OFF.
fl When the starting motor rotates correctly. (If the starting motor also does not rotate, go to E-8)
Cause Remedy
1
• Turn starting switch ON. Is voltage between B01 (K) and NO
• 20 – 30 V chassis normal?
YES
2
• Turn starting switch ON. Is voltage between B01 (J) and NO harness between battery relay Repair or
• 20 – 30 V chassis normal? M and B01 (J) replace
harness inside circuit breaker replace
box or defective circuit
3 breaker
• Turn starting switch ON. Is continuity of diodes D31 and NO
Defective diodes D31, D32 Replace
• 20 – 30 V D32 normal?
harness between B01 (K) and replace
C01 (7),(13)
C-1 Related electrical circuit diagram
20-416 PC750, 800-6

TROUBLESHOOTING C-2
C-2 [E232] Short circuit in pump TVC solenoid system is displayed

fl Always turn the emergency pump drive switch OFF.
Cause Remedy
1
• Turn starting switch Is resistance between C13 NO Defective TVC solenoid
OFF. (male) (1) and (2), (1) and (internal short circuit or short Replace
• Disconnect C13. chassis as shown in Table 1? circuit with ground)
YES
2
• Turn starting switch Is resistance between C02 NO
OFF. (female) (8) and (18), (8) and
• Disconnect C02. chassis as shown in Table 1?
YES
short circuit with power source
3 in wiring harness between C05
• Turn starting switch Is resistance between C05 NO (female) (3) – H12 (3) – C13 Repair or
OFF. (female) (3) and (4), (3) and (female) (1), or short circuit with replace
• Disconnect C05. chassis as shown in Table 1? power source in wiring harness
YES between C05 (female) (4) – H12
(4) – C13 (female) (2)
• Turn starting switch 4 Defective emergency pump
OFF. Is resistance between C05 (male) drive switch (internal short
NO circuit, short circuit with
• Disconnect C05. (1) and (3), (2) and (4), (1) (2) (3) (4) Replace
• Turn TVC emergency and chassis as shown in Table 2? power source)
switch OFF. YES Short circuit with ground or
short circuit with power source Repair or
in wiring harness between C02 replace
(female) (8) – H12 (5) – C05
(female) (1), or short circuit with
power source in wiring harness
between C02 (female) (18) – H12
(6) – C05 (female) (2)
Table 1
Troubleshooting No. 1 Troubleshooting No. 2 Troubleshooting No. 3 Resistance value
Between C13 (male) (1) and (2) Between C02 (female) (8) and (18) Between C05 (female) (3) and (4) 10 – 22 Ω
Between C13 (male) (1) and chassis Between C02 (female) (8) and chassis Between C05 (female) (3) and chassis Min. 1 MΩ
Table 2
Troubleshooting No. 4 Resistance value
Between C05 (male) (1) and (3), (2) and (4) Max. 1 Ω
Between C05 (male) (1) (2) (3) (4) and chassis Min. 1 MΩ
PC750, 800-6 20-417

TROUBLESHOOTING C-2
20-418 PC750, 800-6

TROUBLESHOOTING C-3
C-3 [E233] Disconnection in pump TVC solenoid system is displayed

fl If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid.
If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. 1 A)
continues to flow to the solenoid.
fl Always turn the emergency pump drive switch OFF.
Cause Remedy
1
• Turn starting switch Is resistance between C13 NO Defective TVC solenoid
OFF. (male) (1) and (2), (2) and (internal disconnection or Replace
• Disconnect C13. chassis as shown in Table 1? defective contact)
YES
2
• Turn starting switch Is resistance between C02 NO
OFF. (female) (8) and (18), (18) and
• Disconnect C02. chassis as shown in Table 1?
YES
disconnection in wiring harness
3 between C05 (female) (3) – H12 (3)
• Turn starting switch Is resistance between C05 NO – C13 (female) (1), or defective
OFF. (female) (3) and (4), (4) and Repair or
contact, disconnection, or short
• Disconnect C05. chassis as shown in Table 1? circuit with ground in wiring replace
YES harness between C05 (female) (4)
– H12 (4) – C13 (female) (2)
• Turn starting switch 4 Defective emergency pump

OFF. Is resistance between C05 (male) drive switch (internal defective
NO contact, disconnection, or short
• Disconnect C05. (1) and (3), (2) and (4), (1) (2) (3) (4) Replace
• Turn TVC emergency and chassis as shown in Table 2? circuit with ground)
switch OFF. YES Defective contact or
disconnection in wiring harness Repair or
between C02 (female) (8) – H12 (5) replace
– C05 (female) (1), or defective
contact, disconnection, or short
circuit with ground in wiring
harness between C02 (female)
(18) – H12 (6) – C05 (female) (2)
Table 1
Troubleshooting No. 1 Troubleshooting No. 2 Troubleshooting No. 3 Resistance value
Between C13 (male) (1) and (2) Between C02 (female) (8) and (18) Between C05 (female) (3) and (4) 10 – 22 Ω
Between C13 (male) (2) and chassis Between C02 (female) (18) and chassis Between C05 (female) (4) and chassis Min. 1 MΩ
Table 2
Troubleshooting No. 4 Resistance value
Between C05 (male) (1) and (3), (2) and (4) Max. 1 Ω
Between C05 (male) (1) (2) (3) (4) and chassis Min. 1 MΩ
PC750, 800-6 20-419

TROUBLESHOOTING C-3
20-420 PC750, 800-6

TROUBLESHOOTING C-4
C-4 [E203] Short circuit in swing holding brake solenoid system is

displayed
fl Always turn the swing holding brake release switch OFF, then turn the swing lock switch OFF
before checking.
Cause Remedy
OFF. 1
• Interchange V04 with Interchange connector with NO
other solenoid. Is [E203] Defective swing holding brake
other connector. Replace
displayed? solenoid
• Start engine.
• Operate swing lever. YES
2
• Turn starting switch Is resistance between V04 NO Defective swing holding brake
OFF. (male) (1) and (2), (2) and Replace
solenoid
• Disconnect V04. chassis as shown in Table 1?
YES

3
OFF.
• Disconnect C01. Is resistance between C01 NO
• Turn swing lock switch
(female) (3) and chassis
normal?
OFF.
• 20 – 60 Ω YES

OFF.
4
• Disconnect X05. Is resistance between X05 NO
(female) (3) (4) and chassis Defective swing lock switch Replace
• Turn swing lock switch
normal?
OFF.
• Min. 1 MΩ YES
5 Short circuit with chassis

• Turn starting switch ground in wiring harness Repair or
OFF. Is resistance between X05 NO
(male) (4) and chassis normal? between X05 (male) (4) – X01 replace
• Disconnect X05.
• 20 – 60 Ω (6) – H13 (7) – V04 (female) (2)
YES Short circuit with chassis
ground in wiring harness Repair or
between C01 (female) (3) – replace
D26 (2) (1) – H13 (1) – X01 (7) –
X05 (male) (3)
Table 1
Between V04 (male) (1) and (2) 20 – 60 Ω
Between V04 (male) (2) and chassis Min. 1 MΩ
PC750, 800-6 20-421

TROUBLESHOOTING C-4
20-422 PC750, 800-6

TROUBLESHOOTING C-5
C-5 [E213] Disconnection in swing holding brake solenoid system is

displayed
fl Always turn the swing holding brake release switch OFF, then turn the swing lock switch OFF
before checking.
Note 1: When the swing holding brake release switch is operated, this error [E213] is detected, but it
does not indicate a failure.
Note 2: When the swing lock switch is operated and error [E213] is generated, carry out troubleshoot-
ing of the swing lock signal input system (F-9).
Cause Remedy
OFF. Interchange connector with NO Defective swing holding brake
• Interchange V04 with other solenoid. Is [E213] Replace
displayed? solenoid
other connector.
• Turn starting switch ON. YES

OFF. Is resistance between V04 NO Defective swing holding brake
• Disconnect V04. (male) (1) and (2) normal? Replace
solenoid
• 20 – 60 Ω
YES
3
• Turn starting switch ON. Is voltage between D26 (2) and NO Defective pump controller Replace
• Disconnect D26. chassis as shown in Table 1?
YES

OFF. Is resistance between X05 NO
• Disconnect X05.
Defective swing lock switch Replace
(female) (3) and (4) normal?
• Max. 1 Ω
with power source in wiring
• Turn starting switch 5 harness between X05 (male)
OFF. Is resistance between X05 NO (4) – X01 (6) – H13 (7) – V04 Repair or
• Disconnect X05. (male) (4) and chassis normal? (female) (2) replace
• 20 – 60 Ω
disconnection in wiring harness Repair or
between D26 (female) (1) – H13 replace
(1) – X01 (7) – X05 (male) (3), or
defective contact or
between V04 (female) (1) and
revolving frame GND
Table 1
Troubleshooting No. 3 Voltage Measurement condition
0 – 10 V Approx. 10 seconds after all levers are returned to neutral

Between D26 (1) and chassis
20 – 30 V Swing lever or work equipment lever operated slightly
PC750, 800-6 20-423

TROUBLESHOOTING C-5
20-424 PC750, 800-6

TROUBLESHOOTING C-6
C-6 [E201] Short circuit in CO cancel solenoid system is displayed
Cause Remedy
OFF. Interchange connector with
• Interchange V07 with NO Defective CO cancel solenoid
other solenoid. Is [E201] Replace
other connector. displayed?
• Start engine.
• DH mode YES
2
• Turn starting switch Is resistance between V07 NO
OFF. (male) (1) and (2), (2) and Defective CO cancel solenoid Replace
YES

OFF. Is resistance between C01 NO ground in wiring harness Repair or
• Disconnect C01. (female) (8) and chassis between C01 (female) (8) and replace
• 20 – 60 Ω
normal?
V07 (female) (2)
YES
Table 1
PC750, 800-6 20-425

TROUBLESHOOTING C-7
C-7 [E211] Disconnection in CO cancel solenoid system is displayed
Cause Remedy
1
OFF.
Interchange connector with NO
• Interchange V07 with other solenoid. Is [E211] Defective CO cancel solenoid Replace
other connector. displayed?
• DH mode YES

OFF. Is resistance between V07 NO
• Disconnect V07. (male) (1) and (2) normal? Defective CO cancel solenoid Replace
• 20 – 60 Ω
YES
OFF. Is resistance between C01 NO harness between C01 (8) and Repair or
• Disconnect C01.
(female) (8) and chassis V07 (2), or between V07
normal? replace
• 20 – 60 Ω (female) (1) and chassis
YES
ground
• Disconnect C01 and 4 Short circuit with power

V07. Is voltage between V07 NO source in wiring harness Repair or
• Turn starting switch ON. (female) (2) and chassis as between C01 (female) (8) and replace
• Max. 1 V
shown in Table 1?
V07 (female) (2)
YES
20-426 PC750, 800-6

TROUBLESHOOTING C-8
C-8 [E202] Short circuit in straight-travel solenoid system is displayed

OFF. Cause Remedy
• Interchange V03 with 1
other connector. Interchange connector with
• Start engine. NO Defective straight-travel
other solenoid. Is [E202] Replace
• Operate both left and displayed? solenoid
right travel + work YES
equipment at same
time.
2
• Turn starting switch Is resistance between V03 NO Defective straight-travel
OFF. (male) (1) and (2), (2) and Replace
• Disconnect V03. chassis as shown in Table 1? solenoid
YES

OFF. Is resistance between C01 NO ground in wiring harness Repair or
• Disconnect C01. (female) (2) and chassis between C01 (female) (2) and replace
• 20 – 60 Ω
normal?
V03 (female) (2)
YES
Table 1
PC750, 800-6 20-427

TROUBLESHOOTING C-9
C-9 [E212] Disconnection in straight-travel solenoid system is

displayed
Cause Remedy
OFF. Interchange connector with Defective straight-travel
NO
• Interchange V03 with other solenoid. Is [E212] solenoid (internal Replace
other connector. displayed? disconnection)

OFF. Is resistance between V03 Defective straight-travel
NO
• Disconnect V03. (male) (1) and (2) normal? solenoid (internal Replace
• 20 – 60 Ω disconnection)
YES
• Turn starting switch 3 Defective contact or

OFF. Is resistance between V03 NO disconnection in wiring Repair or
• Disconnect C01. (female) (1) and chassis harness between V03 (female) replace
• Max. 1 Ω
normal? (1) and chassis
YES
When V03 (female) (2) is grounded NO disconnection in wiring
OFF.
• Disconnect V03. to chassis, is resistance between C01 harness between C01 (female) Repair or
(female) (2) and chassis normal? (2) and V03 (female) (2) replace
• Max. 1 Ω
YES

5 Short circuit with power
OFF.
Is voltage between C01 NO
• Disconnect C01 and
(female) (2), V03 (female) (2) source in wiring harness Repair or
V03. and chassis normal? between C01 (female) (2) and replace
• Turn starting switch ON. V03 (female) (2)
• Max. 1 V YES
20-428 PC750, 800-6

TROUBLESHOOTING C-10
C-10 [E204] Short circuit in 2-stage relief solenoid system is displayed

OFF. Cause Remedy
• Interchange V02 with
other connector. 1
• Start engine. Interchange connector with NO Defective 2-stage relief
• Turn heavy lift switch other solenoid. Is [E204] Replace
displayed? solenoid
ON.
• Operate boom RAISE YES
independently and
relieve circuit.
2
• Turn starting switch Is resistance between V02 NO Defective 2-stage relief
OFF. (male) (1) and (2), (2) and solenoid Replace
YES

OFF. Is resistance between C01 NO wiring harness between C01 Repair or
• Disconnect C01. (female) (10) and chassis (female) (10) and V02 (female) replace
• 20 – 60 Ω
normal?
(2)
YES
Table 1
PC750, 800-6 20-429

C-11 [E214] Disconnection in 2-stage relief solenoid system is

displayed
Cause Remedy
• Turn starting switch 1 Defective 2-stage relief
OFF. Interchange connector with NO solenoid (internal
other connector. displayed? disconnection or short circuit
• Turn starting switch ON. YES with power source)
• Turn starting switch 2 Defective 2-stage relief

OFF. Is resistance between V02 NO solenoid (internal
• Disconnect V02. (male) (1) and (2) normal? disconnection or short circuit Replace
• 20 – 60 Ω with power source)
YES
• Turn starting switch harness between C01 (female)
OFF. Is resistance between C01 NO Repair or
(male) (10) and chassis (10) and V02 (female) (2), or
• Disconnect C01.
• 20 – 30 Ω
normal? between V02 (female) (1) and replace
YES chassis ground

• Disconnect C01. Is voltage between C01 NO source in wiring harness Repair or
• Turn starting switch ON. (female) (10) and chassis
ground approx. 0V? between C01 (female) (10) – replace
V02 (female) (2)
YES
20-430 PC750, 800-6

C-12 [E205] Short circuit in swing priority selector solenoid system is

displayed

Cause Remedy
OFF. 1
• Interchange V01 with Interchange connector with NO Defective swing priority
other connector. other solenoid. Is [E205] Replace
• Start engine. displayed? selector solenoid
• Turn swing priority YES
switch ON.
2
• Turn starting switch Is resistance between V01 NO Defective swing priority
OFF. (male) (1) and (2), (2) and selector solenoid Replace
YES

• 20 – 60 Ω
normal?
(2)
YES
Table 1
PC750, 800-6 20-431

C-13 [E211] Disconnection in swing priority selector solenoid system

is displayed
Cause Remedy
OFF. Interchange connector with NO Defective swing priority
other connector. displayed? selector solenoid

OFF. Is resistance between V01 NO Defective swing priority
• Disconnect V01. (male) (1) and (2) normal? selector solenoid Replace
• 20 – 60 Ω
YES
• Turn starting switch harness between C01 (female)
OFF. Is resistance between C01 NO Repair or
(female) (5) and chassis (5) and V01 (female) (2), or
• Disconnect C01.
• 20 – 60 Ω
normal? between V01 (female) (1) and replace
YES chassis ground

OFF. Short circuit with power
Is voltage between V01 NO source in wiring harness Repair or
• Disconnect C01 and (female) (2) and chassis
V01. normal? between C01 (female) (5) and replace
• Max. 1 V YES
20-432 PC750, 800-6

C-14 [E206] Short circuit in travel speed solenoid system is displayed

OFF.
• Interchange V06 with
Cause Remedy
other connector. 1
• Start engine. Interchange connector with Defective travel speed
NO
• Set travel speed switch other solenoid. Is [E206] solenoid (internal short circuit, Replace
to Hi. displayed? short circuit with ground)
• Operate travel lever YES
slightly.
• Engine at full throttle.
2
• Turn starting switch Is resistance between V06 Defective travel speed
NO solenoid (internal short circuit, Replace
OFF. (male) (1) and (2), (2) and
• Disconnect V06. chassis as shown in Table 1? short circuit with ground)
YES

• 20 – 60 Ω
normal?
(2)
YES
Table 1
PC750, 800-6 20-433

C-15 [E216] Disconnection in travel speed solenoid system is displayed
Cause Remedy
• Turn starting switch 1 Defective travel speed
OFF. Interchange connector with NO solenoid (internal
displayed? disconnection or short circuit
other connector.
• Turn starting switch ON. YES with power source)
• Turn starting switch 2 Defective travel speed

OFF. Is resistance between V06 NO solenoid (internal
• Disconnect V06. (male) (1) and (2) normal? disconnection or short circuit Replace
• 20 – 60 Ω with power source)
YES

OFF. Is resistance between V06 NO disconnection in wiring Repair or
• Disconnect C01 and (female) (1) and chassis
V06. harness between V06 (female) replace
normal? (1) and chassis
• Max. 1 Ω YES
When V06 (female) (2) is grounded NO disconnection in wiring
OFF.
• Disconnect V06. to chassis, is resistance between C01 harness between C01 (female) Repair or
(female) (9) and chassis normal? (9) and V06 (female) (2) replace
• Max. 1 Ω
YES

OFF. 5 Short circuit with power
• Disconnect C01 and Is voltage between C01 NO
(female) (9), V06 (female) (2) source in wiring harness Repair or
V06. between C01 (female) (9) and
and chassis normal? replace
• Max. 1 V YES
C-15 Related electric circuit diagram
20-434 PC750, 800-6

C-16 [E217] Model selection input error is displayed
Cause Remedy
1
• Turn starting switch ON. Is monitoring mode display as NO
• Set to monitoring
mode [02] and [21, 22].
shown in Table 1?
YES
2 Defective model selection

Is voltage between C17(5) (6) connector or disconnection,
• Turn starting switch ON. NO short circuit, or short circuit Repair or
(7) (13) (14) and chassis as
shown in Table 2? with ground in wiring harness replace
YES with defective voltage
Table 1 Display of monitoring code

Display of model code Display of model selection signal input status
Monitoring code 02 Monitoring code 22 Monitoring code 27
fl The diagram shows monitoring code 02.

fl Check the display of the bit pattern marked with the arrow ().
Table 2 Voltage of wiring harness

Between (5) Between (6) Between (7) Between (13) Between (14)
C-17
and chassis and chassis and chassis and chassis and chassis
Voltage 20 – 30 V 20 – 30 V Max. 1 V 20 – 30 V 20 – 30 V
PC750, 800-6 20-435

20-436 PC750, 800-6

C-17 [E227] Abnormality in engine speed sensor system is displayed
Cause Remedy
1 Defective engine speed sensor
OFF. Is resistance between ENE NO (internal defective contact,
• Disconnect ENE. (male) (1) and (2) normal? disconnection, short circuit Replace
• 500 – 1000 Ω with ground)
YES
Defective contact,
2 with ground in wiring harness
OFF. Is resistance between C16 NO between C16 (female) (1) and Repair or
• Disconnect C16. (female) (1) and (2) normal? ENE (female) (2) or C16 (female) replace
• 500 – 1000 Ω (2) and ENE (female) (1)
YES
PC750, 800-6 20-437

C-18 Abnormality in machine push-up solenoid system (no service

code displayed)
fl Even if an abnormality occurs in the machine push-up solenoid system, no service code is dis-
played on the monitor panel.
a) Even when machine push-up switch is set to low pressure, solenoid is not switched ON
fl Check that fuse 2 is not blown.
fl Carry out troubleshooting with the machine push-up switch at low pressure.
Cause Remedy
1
• Turn starting switch ON. Is voltage between V05 (2) and NO
• 20 – 30 V chassis normal?
YES
2 Defective machine push-up

• Turn starting switch solenoid (internal
OFF. Is resistance between V05 NO disconnection, defective Replace
• Disconnect V05. (male) (1) and (2) normal?
• 20 – 60 Ω contact)
harness between V05 (female) replace
(1) and chassis
3
Defective fuse 2, or defective
• Turn starting switch ON. Is voltage between M38 (2) NO Repair or
contact or disconnection in
• 20 – 30 V and chassis normal?
wiring harness between fuse 2 replace
YES – X01 (12) – M38 (male) (2)
• Turn starting switch 4 Defective machine push-up

OFF.
• Disconnect M38.
Is resistance between M38 NO switch (internal disconnection, Replace
• Switch ON: Max. 1 Ω (female) (1) and (2) normal? defective contact)
• Switch OFF: Min. 1 MΩ YES Defective contact,
disconnection, or short circuit Repair or
between M38 (male) (1) – X01
(16) – H13 (3) – V05 (female) (2)
20-438 PC750, 800-6

b) Even when machine push-up switch is set to high pressure, solenoid is not switched OFF
fl Carry out troubleshooting with the machine push-up switch at high pressure.
Cause Remedy
1
• Turn starting switch ON. Is voltage between V05 (2) and NO
• Max. 1 V chassis normal?
YES
Defective machine push-up
Replace
solenoid
Short circuit with power
2 source in wiring harness
• Turn starting switch ON. NO between M38 (male) (1) – X01 Repair or
Is voltage between M38 (1)
• Max. 1 V (16) – H13 (3) – V05 (female) replace
and chassis normal?
(2)
YES
Defective machine push-up
solenoid (internal short circuit Replace
with power source)
PC750, 800-6 20-439

C-19 Abnormality in shockless boom solenoid system (no service code

displayed)
fl Even if an abnormality occurs in the shockless boom solenoid system, no service code is displayed
on the monitor panel.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
fl Solenoid V09: RAISE; solenoid V10: LOWER
a) Shockless mode cannot be canceled (solenoid is not switched ON)

(If the fuse is blown, check for a short circuit with the ground in the wiring harness.)
Cause Remedy
OFF. 1
• Between (2) and (1): Is resistance between V09 (V10) NO
20 – 60 Ω (male) (2) and (1), and between Defective solenoid at end
Replace
• Between (2) and (2) and chassis normal? where resistance is defective
chassis: Min. 1 MΩ YES
• Disconnect V09, V10.
2
• Turn shockless switch Is voltage between V09 (V10) NO
ON. (2) and chassis normal?
• 20 – 30 V
YES
Solenoid which is not
Replace
actuated is defective
3
• Turn starting switch ON. Is voltage between M33 (1) NO
• 20 – 30 V and chassis normal?
YES
4
• Turn shockless switch Is voltage between M33 (3) NO Defective shockless switch Replace
ON. and chassis normal?
• 20 – 30 V
YES
• Turn shockless switch Is voltage between R15 (1) and NO Repair or
harness between M33
ON. chassis normal? replace
• 20 – 30 V (female) (3) – X01 (19) – R15
YES (female) (1)
Go to Item 8 on next page Go to Item 6 on next page
Note
Shockless switch Mode
ON Shockless mode canceled
OFF Shockless mode
20-440 PC750, 800-6

From Item 3 on From Item 5 on

previous page previous page
Cause Remedy
6
• 20 – 30 V Is voltage between R15 (5) and NO
• Turn shockless switch chassis normal?
ON. Defective contact or
YES disconnection in wiring
harness between R15 (female) Repair or
(5) – H13 (13) – V09 (V10) replace
(female) (2)
7
• Turn starting switch Defective contact or
OFF. Is resistance between R15 NO disconnection in wiring Repair or
• Disconnect R15. (female) (2) and chassis
normal? harness between R15 (female) replace
• Max. 1 Ω (2) and H15 (1)
YES
Defective shockless relay
Replace
(R15)
8
• Turn starting switch ON. Is voltage between fuse 2 NO
• 20 – 30 V Blown fuse 2 Replace
outlet and chassis normal?
harness between fuse 2 – X01 replace
(9) – M33 (female) (1)
PC750, 800-6 20-441

b) Shockless mode is not actuated
Cause Remedy
1
Is voltage between V09 (V10) NO
• Switch OFF: Max. 1 V
• Switch ON: 20 – 30 V (2) and chassis normal?
YES
Defective operation of Correct or
solenoid valve replace
2
• Turn starting switch ON. Is voltage between R15 (1) and NO
• Switch OFF: Max. 1 V
• Switch ON: 20 – 30 V
chassis normal?
YES

• Turn starting switch ON. When relay 15 is removed, is source in wiring harness
NO Repair or
• Max. 1 V voltage between R15 (female) between R15 (female) (5) –
• Remove R15. (5) and chassis normal? H13 (13) – V09 (V10) (female) replace
YES (2)
Defective shockless relay Replace

OFF. Is resistance of shockless NO
• Switch OFF: Min. 1 MΩ Defective shockless switch Replace
switch normal?
• Switch ON: Max. 1 Ω
• Disconnect M33. YES Short circuit with power
between M33 (female) (3) – replace
X01 (19) – R15 (female) (1)
Table 1
Shockless switch Mode
ON Shockless mode canceled
OFF Shockless mode
C-19 Related electric circuit diagram
20-442 PC750, 800-6

C-20 [E207] Short circuit in flash light relay drive system is displayed
fl If [E207] is not displayed, and the flash light does not light up, go to C-21 Flash light relay does not
work.
Cause Remedy
OFF. 1
• Interchange relay. Interchange with other relay. Is NO
• Start engine. [E207] displayed?
• Turn flash light switch
ON. YES
Defective flash light drive
Replace
relay
OFF. 2
• Disconnect C01 and Is resistance between chassis and wiring NO Short circuit with ground in
Repair or
R16. harness between C01 (female) (11) and wiring harness between C01
R16 (female) (1) normal? replace
• Between wiring (11) and R16 (1)
harness and chassis: YES
Min. 1 MΩ
PC750, 800-6 20-443

C-21 Flash light relay does not work

fl First, check monitoring code: bit pattern 24-(2) to see if the horn switch input is normal.
(F-14: When horn switch is ON, bit pattern 24-(2) does not go out.)
fl If [E207] is displayed, go to C-20 [E207] Short circuit in flash light relay drive system is displayed.
Cause Remedy
OFF.
• Interchange R16 relay.
Interchange with other relay. Is NO
• Start engine. movement normal?
• Turn horn switch ON. YES
Defective flash light drive
relay Replace

OFF.
Is resistance between C01 disconnection in wiring Repair or
• Disconnect C01 and (female) (11) and R16 (female) NO
R16. (1) normal? harness between C01 (11) and replace
• Between C01 (11) and R16 (1)
R16 (1): Max. 1 Ω YES

OFF. Is resistance between R16
• Disconnect R16. NO disconnection in wiring Repair or
(female) (2) and chassis
• Between R16 (2) and normal? harness between R16 (2) and replace
chassis : Max. 1 Ω chassis
YES
4
When horn switch is ON, do NO
• Turn starting switch ON. relay contacts making clicking Defective pump controller Replace
sound?
YES
Defective contact,
5
NO Repair or
• Voltage of R16 (3): with ground in wiring harness
Is voltage of R16 (3) normal? replace
20 – 30 V between fuse 6 – H12 (13) –
YES R16 (3)
OFF.
• Disconnect R16 and 6 Defective contact,
M82. Is resistance between R16 (male) (5) NO disconnection, or short circuit Repair or
• Between R16 and M82: – M80 – M82 (female) normal, and is with ground in wiring harness replace
Max. 1 Ω circuit insulated from chassis? between R16 (5) – M80 – M82
• Between wiring YES
harness and chassis: Blown flash light bulb or Repair or
Min. 1 Ω defective contact of flash light replace
GND
20-444 PC750, 800-6

C-22 [E231] Abnormality (short circuit) in power source holding relay

output system for step light is displayed
fl If [E231] is not displayed, and the step light does not light up only when the key is OFF and the
step light switch is kept pressed for at least 1 second (the step light can light up when the key is
ON), go to C-25 Step light does not light up.
Cause Remedy
OFF. 1
• Leave key switch at [E231] displayed?
OFF position and turn
step light switch ON. YES
Defective step light power
Replace
source drive relay
OFF.
• Disconnect C02 and 2
Is resistance between chassis power Short circuit with power
R25. NO Repair or
source and wiring harness between C02 source in wiring harness
• Between wiring
(female) (6) and R25 (female) (2) normal? replace
harness and chassis between C02 (6) and R25 (2)
power source: YES
Min. 1 MΩ Defective pump controller Replace
PC750, 800-6 20-445

C-23 Step light switch does not work

fl The step light can light up when the key is at ON, but when the key is at OFF and the step light
switch is kept pressed for at least 1 second, the step light does not light up.
fl First, check monitoring code: bit pattern 24-(1) to see if the step light switch input is normal.
(F-13: When step light switch is ON, bit pattern 24-(1) does not go out.)
fl If [E231] is displayed, go to C-22 [E231] Abnormality (short circuit) in power source holding relay
output system for step light.
Cause Remedy
OFF. 1
• Leave key switch at movement normal?
step light switch ON. YES
Defective power source
holding relay for step light Replace
OFF.
R25. 2 Defective contact,
• Between C02 (6) and Is resistance between C02 (female) (6)
R25 (2): Max. 1 Ω NO disconnection, or short circuit Repair or
and R25 (female) (2) normal, and is
• Between wiring circuit insulated from chassis? with ground in wiring harness replace
harness and chassis: between C02 (6) and R25 (2)
Min. 1 MΩ YES
• Turn starting switch Defective contact,
OFF. 3
• Leave key switch at Is voltage between R25 disconnection, or short circuit
NO Repair or
OFF position and turn (female) (1) and chassis with ground in wiring harness
replace
step light switch ON. normal? between fuse 14 – H14 (6) –
• Voltage between R25 (2) YES R25 (1)
and chassis: 20 – 30 V
4
• Leave key switch at
When step light switch is ON, NO
OFF position and turn Defective pump controller Replace
step light switch ON. do relay contacts move?
YES
Defective contact,
• Leave key switch at 5 with ground in wiring harness
NO between fuse 14 – H14 (6) – Repair or
step light switch ON. Is voltage of R25 (3) normal? replace
R25 (3)
• Voltage of R25 (3):
20 – 30 V YES Defective contact,
with ground in wiring harness Repair or
between R25 (5) – D34 (2) (1) – replace
C01 (7) (13)
20-446 PC750, 800-6

C-24 [E302] Short circuit in step light relay drive system is displayed
fl If [E302] is not displayed, and the step light does not light up, go to C-26 Step light relay does not
light up.
Cause Remedy
OFF.
1
• Start engine. [E302] displayed?
• Turn step light switch
ON. YES
Defective step light drive relay Replace

OFF. 2
• Disconnect C01 and Is resistance between chassis and wiring NO Short circuit with ground in
Repair or
R17. harness between C01 (female) (1) and R17 wiring harness between C01
(female) (1) normal? replace
• Between wiring (1) and R17 (1)
harness and chassis: YES
Min. 1 MΩ
PC750, 800-6 20-447

C-25 [303] Disconnection in step light relay drive system is displayed

fl If [E303] is not displayed, and the step light does not light up, go to C-26 Step light does not light
up.
Cause Remedy
OFF.
1
• Interchange R17 relay. Interchange with other relay. Is NO
• Start engine. movement normal?
• Turn step light switch
ON. YES
Defective step light drive relay Replace

OFF.
Is resistance between C01 NO disconnection in wiring Repair or
(female) (1) and R17 (female)
R17. (1) normal? harness between C01 (1) and replace
• Between C01 (1) and R17 (1)
R17 (1): Max. 1 Ω YES
• Turn starting switch ON. 3 Defective contact or

• Disconnect R17. Is resistance between R17 NO disconnection in wiring Repair or
• Between R17 (2) and (female) (2) and chassis harness between R17 (2) and replace
chassis: Max. 1 Ω normal?
chassis
YES
• Turn starting switch ON. 4

• When step light switch When step light switch is ON, NO
is ON, voltage Defective pump controller Replace
between C01 (1) and
is voltage of C01 (1) normal?
Defective contact,
chassis: 20 – 30 V YES disconnection, or short circuit
between fuse 14 – H14 (6) –
R17 (3), or
Defective contact, Repair or
disconnection, or short circuit replace
between R17 (5) – M72 (3) –
M73 (3) – M75, or Blown step
light bulb or defective contact
of step light GND
20-448 PC750, 800-6

C-26 Step light does not light up

fl First, check monitoring code: bit pattern 24-(1) to see if the step light switch input is normal.
(F-12: When step light switch is ON, bit pattern 24-(1) does not go out)
fl If the step light can light up when the key is ON, but when the key is OFF, the step light does not
light up continuously for 60 seconds when the switch is pressed, go to C-23 Step light switch does
not work.
fl If [E302] is displayed, go to C-24 [E302] Short circuit in step light relay drive system is displayed
fl If [E303] is displayed, go to C-25 Disconnection in step light relay drive system is displayed.
Cause Remedy
ON. NO disconnection, or short circuit Repair or
• Voltage of R17 (3): Is voltage of R17 (3) normal?
20 – 30 V between fuse 14 – H14 (6) –
YES
• Turn starting switch R17 (3)
OFF. Defective contact,
• Disconnect R17 and 2 disconnection, or short circuit
M75. Is resistance between R17 (female) (5) – NO Repair or
M72 (3) – M73 (3) – M75 (female) normal, with ground in wiring harness
• Between R17 (5) and
M75: Max. 1 Ω and is circuit insulated from chassis? between R17 (5) – M72 (3) – replace
• Between wiring YES M73 (3) – M75
harness and chassis: Blown step light bulb or Repair or
Min. 1 Ω defective contact of step light replace
GND
PC750, 800-6 20-449

C-27 [E228] Abnormality in auto-deceleration output system is

displayed
Cause Remedy
1
• Turn auto-deceleration Is voltage between C01 (4) and NO
switch OFF. chassis ground normal?
• Min. 5 V
YES
• Turn starting switch 2 Short circuit with ground in

OFF. Is resistance between C01
• Disconnect C01 and NO wiring harness between C01
(female) (4) and chassis Replace
E14. ground normal? (female) (4) and E14 (female)
• Min. 1 Ω (11)
YES

OFF. Is resistance between C01 disconnection in wiring
NO Repair or
• Disconnect C01 and (female) (4) and E14 (female) harness between C01 (female)
replace
E14. (11) normal? (4) and E14 (female) (11)
• Max. 1 Ω YES
20-450 PC750, 800-6

TROUBLESHOOTING OF ENGINE THROTTLE &
PUMP CONTROLLER (INPUT SIGNAL SYSTEM)
(F MODE)
Electrical circuit diagram for F mode ...................................................................................................20-502

F- 1 [Bit pattern 20-(1)] Swing oil pressure switch does not light up ...........................................20-504
F- 2 [Bit pattern 20-(2)] R.H. travel oil pressure switch does not light up ....................................20-505
F- 3 [Bit pattern 20-(3)] Boom LOWER oil pressure switch does not light up .............................20-506
F- 4 [Bit pattern 20-(4)] Boom RAISE oil pressure switch does not light up ................................20-507
F- 5 [Bit pattern 20-(5)] Arm IN oil pressure switch does not light up .........................................20-508
F- 6 [Bit pattern 20-(6)] Arm OUT oil pressure switch does not light up .....................................20-509
F- 7 [Bit pattern 21-(1)] Bucket CURL oil pressure switch does not light up ...............................20-510
F- 8 [Bit pattern 21-(2)] Bucket DUMP oil pressure switch does not light up ..............................20-511
F- 9 [Bit pattern 20-(5)] L.H. travel oil pressure switch does not light up ....................................20-512
F-10 [Bit pattern 21-(4)] Service oil pressure switch does not light up .........................................20-513
F-11 [Bit pattern 21-(3)] Swing lock switch does not light up ........................................................20-514
F-12 [Bit pattern 24-(1)] When step light switch is ON, it does not go out ..................................20-515
F-13 [Bit pattern 24-(2)] When horn switch is ON, it does not go out ...........................................20-516
PC750, 800-6 20-501

TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR F MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE SYSTEM
20-502 PC750, 800-6

TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR F MODE SYSTEM
PC750, 800-6 20-503

TROUBLESHOOTING F-1
F-1 [Bit pattern 20-(1)] Swing oil pressure switch does not light up
¤ Before operating the swing lever, set the swing lock switch to ON.
fl If there is no display only when the swing lever is operated in one direction, the PPC shuttle valve
is defective (go to H-5).
(When measuring with the engine stopped, charge the accumulator before starting.)
Cause Remedy
• Start engine. 1
• Swing lever at neutral: Is voltage between C16 (5) and NO
20 – 30 V chassis ground normal?
• Swing lever operated:
Max. 1 V YES
• Disconnect S08 (S10).

• Start engine. 2 Defective swing oil pressure
• Swing lever at neutral: Is resistance between S08 (S10) NO switch (if problem is not
Min. 1 MΩ (male) (1) and (2) normal, and is Replace
removed even when switch is
• Swing lever operated: circuit insulated from chassis?
replaced, go to H-5)
Max. 1 Ω YES
• See Note 1. Disconnection, defective
contact, or short circuit with
• Turn starting switch 3 ground in wiring harness
OFF. Is resistance between C16 (female) (5) and between C16 (female) (5) and Repair or
• Disconnect C16 and S08 (female) (2) or between C16 (female) NO
(5) and S10 (female) (2) normal, and is S08 (female) (2) or between C16 replace
S08 (S10). circuit insulated from chassis? (female) (5) and S10 (female) (2)
• Between C16 and S08 YES
(S10): Max. 1 Ω Defective contact or
• Between wiring disconnection in wiring harness Repair or
harness and chassis: between S08 (female) (1) and replace
Min. 1 MΩ chassis ground or between S10
(female) (1) and chassis ground
Note 1: It is also possible to fit a short connector and judge the condition.
In this case, check the voltage between C16 (5) and the chassis.
• If it is 20 – 30 V: Go to YES
• If it is less than 1 V: Go to NO
F-1 Related electrical circuit diagram
20-504 PC750, 800-6

TROUBLESHOOTING F-2
F-2 [Bit pattern 20-(2)] R.H. travel oil pressure switch does not light up
¤ Before operating the travel lever, check that the area around the machine is safe.
¤ When measuring with the engine started, operate the travel levers slightly (do not make the
machine move).
Cause Remedy
• Start engine. 1
• Travel lever at neutral: Is voltage between C16 (13) NO
20 – 30 V and chassis ground normal?
• Travel lever operated:
Max. 1 V YES

• Start engine. 2 Defective travel oil pressure
• Travel lever at neutral: Is resistance between S01 (S11) NO
Min. 1 MΩ
switch (if problem is not
(male) (1) and (2) normal, and is Replace
• Travel lever operated: removed even when switch is
circuit insulated from chassis? replaced, go to H-5)
Max. 1 Ω
• See Note 1.
YES
Disconnection, defective contact,
or short circuit with ground in
• Turn starting switch 3 wiring harness between C16
OFF. Is resistance between C16 (female) (13)
Repair or
• Disconnect C16 and and S01 (female) (2) or between C16 NO (female) (13) and S01 (female) (2)
S50.
(female) (13) and S11 (female) (2) normal, or between C16 (female) (13) and replace
and is circuit insulated from chassis?
• Between C16 and S50: S11 (female) (2)
YES
Max. 1 Ω Defective contact or
Min. 1 MΩ chassis ground or between S11
(female) (1) and chassis ground
PC750, 800-6 20-505

TROUBLESHOOTING F-3
F-3 [Bit pattern 20-(3)] Boom LOWER oil pressure switch does not
light up
¤ When measuring with the engine started, operate the work equipment levers slightly (do not make
the work equipment move).
Cause Remedy
• Start engine. 1
• Boom lever at neutral: Is voltage between C17 (10) NO
• Boom lever operated
to LOWER: Max. 1 V YES
• Disconnect S04.
• Start engine. 2 Defective boom LOWER oil
• Boom lever at neutral: Is resistance between S04 (male) NO pressure switch (if problem is
Min. 1 MΩ (1) and (2) normal, and is circuit Replace
not removed even when
• Boom lever operated insulated from chassis?
switch is replaced, go to H-5)
to LOWER: Max. 1 Ω YES
• Turn starting switch 3 contact, or short circuit with
OFF. Is resistance between C17 (female) NO ground in wiring harness
Repair or
• Disconnect C17 and (10) and S04 (female) (2) normal, and between C17 (female) (10) –
replace
S04. is circuit insulated from chassis? H13 (11) – S04 (female) (2)
• Between C17 and S04: YES
• Between wiring disconnection in wiring Repair or
harness and chassis: harness between S04 (female) replace
Min. 1 MΩ (1) and chassis ground
20-506 PC750, 800-6

TROUBLESHOOTING F-4
F-4 [Bit pattern 20-(4)] Boom RAISE oil pressure switch does not light
up
Cause Remedy
• Start engine. 1
• Boom lever at neutral: Is voltage between C17 (2) and NO
• Boom lever operated
to RAISE: Max. 1 V YES
• Disconnect S02.
• Start engine. 2 Defective boom RAISE oil
• Boom lever at neutral: Is resistance between S02 (male) NO pressure switch (if problem is
• Boom lever operated insulated from chassis?
to RAISE: Max. 1 Ω YES
OFF. Is resistance between C17 (female) (2)
Repair or
• Disconnect C17 and and D28 (female) (2), between D28 NO between C17 (female) (2) –
S02.
(female) (1) and S02 (female) (2) normal, H13 (9) – D28 (2),(1) – S02 replace
and is circuit insulated from chassis?
• Between C17 and S02: YES (female) (2)
• Between wiring Repair or
harness and chassis: replace
Min. 1 MΩ
harness between S02 (female)
(1) and chassis ground
PC750, 800-6 20-507

TROUBLESHOOTING F-5
F-5 [Bit pattern 20-(5)] Arm IN oil pressure switch does not light up
Cause Remedy
• Start engine. 1
• Arm lever at neutral: Is voltage between C17 (3) and NO
• Arm lever operated to
IN: Max. 1 V YES
• Disconnect S05.
• Start engine. 2 Defective arm IN oil pressure
• Arm lever at neutral: Is resistance between S05 (male) NO switch (if problem is not
removed even when switch is
• Arm lever operated to insulated from chassis?
replaced, go to H-5)
IN: Max. 1 Ω YES
• See Note 1.
Disconnection, defective
OFF. Is resistance between C17 (female) NO ground in wiring harness Repair or
• Disconnect C17 and (3) and S05 (female) (2) normal, and between C17 (female) (3) – replace
S05. is circuit insulated from chassis?
• Between C17 and S05: H13 (10) – S05 (female) (2)
YES
20-508 PC750, 800-6

TROUBLESHOOTING F-6
F-6 [Bit pattern 20-(6)] Arm OUT oil pressure switch does not light up
Cause Remedy
• Start engine. 1
• Arm lever at neutral: Is voltage between C17 (11) NO
• Arm lever operated to
OUT: Max. 1 V YES
• Disconnect S03.
• Start engine. 2 Defective arm OUT oil
• Arm lever at neutral: Is resistance between S03 (male) NO pressure switch (if problem is
• Arm lever operated to insulated from chassis?
OUT: Max. 1 Ω YES
Repair or
• Disconnect C17 and (11) and S03 (female) (2) normal, and between C17 (female) (11) –
replace
S03. is circuit insulated from chassis? H13 (12) – S03 (female) (2)
PC750, 800-6 20-509

TROUBLESHOOTING F-7
F-7 [Bit pattern 21-(1)] Bucket CURL oil pressure switch does not light
up
Cause Remedy
• Start engine. 1
• Bucket lever at neutral: Is voltage between C16 (11) NO
• Bucket lever operated
to CURL: Max. 1 V YES
• Disconnect S06.
• Start engine. 2 Defective bucket CURL oil
• Bucket lever at neutral: Is resistance between S06 (male) NO pressure switch (if problem is
• Bucket lever operated insulated from chassis?
to CURL: Max. 1 Ω YES
Repair or
• Disconnect C16 and (11) and S06 (female) (2) normal, and between C16 (female) (11) and
replace
S06. is circuit insulated from chassis? S06 (female) (2)
20-510 PC750, 800-6

TROUBLESHOOTING F-8
F-8 [Bit pattern 21-(2)] Bucket DUMP oil pressure switch does not
light up
Cause Remedy
• Start engine. 1
• Bucket lever at neutral: Is voltage between C16 (12) NO
• Bucket lever operated
to DUMP: Max. 1 V YES
• Disconnect S07.
• Start engine. 2 Defective bucket DUMP oil
• Bucket lever at neutral: Is resistance between S07 (male) NO pressure switch (if problem is
• Bucket lever operated insulated from chassis?
to DUMP: Max. 1 Ω YES
Repair or
replace
PC750, 800-6 20-511

TROUBLESHOOTING F-9
F-9 [Bit pattern 20-(5)] L.H. travel oil pressure switch does not light up
¤ When measuring with the engine started, operate the travel levers slightly (do not make the
chassis move).
Cause Remedy
• Start engine. 1
• Travel lever at neutral: Is voltage between C03 (10) NO
• Travel lever operated:
Max. 1 V YES

• Start engine. 2 Defective travel oil pressure
• Travel lever at neutral: Is resistance between S12 (S13) NO
Min. 1 MΩ
switch (if problem is not
• Travel lever operated: removed even when switch is
circuit insulated from chassis?
Max. 1 Ω replaced, go to H-5)
• See Note 1.
YES
OFF. Is resistance between C03 (female) (10) between C03 (female) (10) and Repair or
• Disconnect C03 and and S12 (female) (2) or between C03 NO
(female) (10) and S13 (female) (2) normal, S12 (female) (2) or C03 (female) replace
S12 (S13). and is circuit insulated from chassis? (10) and S13 (female) (2)
• Between C03 and S12 YES
(S13): Max. 1 Ω Defective contact or
Min. 1 MΩ chassis ground or S13 (female)
(1) and chassis ground
20-512 PC750, 800-6

TROUBLESHOOTING F-10
F-10 [Bit pattern 21-(4)] Service oil pressure switch does not light up
Cause Remedy
• Start engine. 1
• Work equipment lever Is voltage between C16 (14) NO
at neutral: 20 – 30 V and chassis ground normal?
• Work equipment lever
operated: Max. 1 V YES
• Disconnect S09.
• Start engine. 2 Defective bucket DUMP oil
• Work equipment lever Is resistance between S09 (male) NO
at neutral: Min. 1 MΩ
pressure switch (if problem is
(1) and (2) normal, and is circuit Replace
• Work equipment lever not removed even when
insulated from chassis?
operated: Max. 1 Ω switch is replaced, go to H-5)
• See Note 1.
YES
Repair or
replace
• If it is 20 – 30V: Go to YES
• If it is less than 1V: Go to NO
PC750, 800-6 20-513

F-11 [Bit pattern 21-(3)] Swing lock switch does not light up
fl Check that the display on the monitor panel is normal. (If the swing lock lamp does not light up,
carry out troubleshooting for M-21 first.)
Cause Remedy
• Turn starting switch ON. 1
• Swing lock switch ON: Is voltage between C17 (16) NO
Max. 1 V and chassis ground normal?
• Swing lock switch OFF:
20 – 30 V YES

OFF. 2
• Disconnect X05. Is resistance between X05
• Swing lock switch ON: (female) (1) and (2) normal, and NO Defective swing lock switch Replace
Max. 1 Ω is circuit insulated from chassis?
• Swing lock switch OFF: YES
Min. 1 MΩ Disconnection, defective
OFF. Is resistance between C17 (female) ground in wiring harness
NO Repair or
• Disconnect C17 and (16) and X05 (male) (1) normal, and between C17 (female) (16) –
replace
X05. is circuit insulated from chassis? X01 (4) – X05 (male) (1)
• Between C17 and X05: YES
harness and chassis: harness between X05 (male) replace
Min. 1 MΩ (2) – X01 (5) – H14 (female) (7)
– chassis ground
20-514 PC750, 800-6

F-12 [Bit pattern 24-(1)] When step light switch is ON, it does not go out
fl If the step light does not light up, check this item, then go to C-26 Step light does not light up.
Cause Remedy
• Start engine. 1
• Step light switch OFF: Is voltage between C16 (7) and NO
• Step light switch ON:
Max. 1 V YES
• Disconnect L03.
• Start engine. 2
• Step light switch OFF: Is resistance between L03
Min. 1 MΩ (female) (1) and (2) normal, and NO Defective step light switch Replace
• Step light switch ON: is circuit insulated from chassis?
Max. 1 Ω YES
• See Note 1. Defective contact,
• Turn starting switch 3 disconnection, or short circuit
OFF. Is resistance between C16 (female) NO with ground in wiring harness
Repair or
• Disconnect C16 and (7) and L03 (female) (1) normal, and between C16 (female) (7) –
replace
L03. is circuit insulated from chassis? M81 (1) – L03 (female) (1)
• Between C16 and L03: YES
harness and chassis: harness between L03 (female) replace
Min. 1 MΩ (2) – M81 (2) – chassis ground
• If it is 20 – 30V: Go to YES
• If it is less than 1V: Go to NO
PC750, 800-6 20-515

F-13 [Bit pattern 24-(2)] When horn switch is ON, it does not go out
fl If the flash light does not light up, check this item, then go to C-21 Flash light does not light up.
Cause Remedy
• Start engine. 1
• Horn switch OFF: NO
Is voltage between C16 (15)
20 – 30 V
• Horn switch ON: and chassis ground normal?
Max. 1 V YES
• Interchange R18 relay

with other relay. 2
• Start engine. Interchange horn switch relay NO
• When horn switch is R18. Does condition return to
pressed, does bit normal?
pattern 24-(2) go out? YES
Defective horn switch relay
Replace
R18
• Disconnect M23.
• Start engine. 3
• Horn switch OFF: Is resistance between M23 Defective horn switch
Min. 1 MΩ NO (including wiring harness up
• Horn switch ON: circuit insulated from chassis? to M23)
Max. 1 Ω
YES
OFF.
• Disconnect C16 and 4 Defective contact,
R18. Is resistance between C16 (female) NO disconnection, or short circuit
• Between C16 and R18: (15) – D35 – R18 (female) (5) normal, with ground in wiring harness Repair or
Max. 1 Ω and is circuit insulated from chassis? between C16 (female) (15) – replace
• Between wiring YES D35 – R18 (female) (5)
harness and chassis:
Min. 1 MΩ
OFF. Is resistance between R18 disconnection in wiring
NO
• Disconnect R18. (female) (3) (2) and chassis harness between R18 (female) Repair or
• Both R18 (3) and (2): normal? (3) and chassis, or between replace
Max. 1 Ω YES R18 (female) (2) and chassis
• Turn starting switch Defective contact,
OFF. 6 disconnection, or short circuit
• Disconnect R18 and Is resistance between R18 (female) NO with ground in wiring harness
M23.
Repair or
(1) and M23 (female) (2) normal, and between R18 (female) (1) and replace
• Between R18 and M23: is circuit insulated from chassis?
Max. 1 Ω M23 (female) (2)
YES
• Between wiring Defective contact,
harness and chassis: disconnection, or short circuit Repair or
Min. 1 MΩ with ground in wiring harness replace
between M23 (female) (1) –
H12 (13) – fuse 6
20-516 PC750, 800-6

TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
Table of failure modes and causes ......................................................................................................20-552

Before carrying out troubleshooting of hydraulic system (H mode) ................................................20-554
All work equipment, travel, swing
H-1 Speeds of all work equipment, swing, travel are slow or lack power ............................ 20-557
H-2 There is excessive drop in engine speed, or engine stalls ..............................................20-558
H-3 No work equipment, travel, swing move ...........................................................................20-560
H-4 Abnormal noise generated (around pump) ........................................................................20-561
H-5 Auto-deceleration does not work ........................................................................................20-561
Work equipment
H-6 Work equipment speed is slow (boom, arm, bucket) .......................................................20-562
H-7 Work equipment (boom, arm, bucket) does not move
(but travel and swing are normal) .......................................................................................20-564
H-8 Excessive hydraulic drift .......................................................................................................20-564
H-9 Excessive time lag .................................................................................................................20-565
H-10 Excessive shock when boom is stopped ............................................................................20-565
H-11 Defective actuation of machine push-up function .............................................................20-565
H-12 Travel deviation is excessive during compound operations ............................................20-566
H-13 Machine deviates naturally to one side during travel operations ...................................20-567
H-14 Deviation is excessive when srtarting ................................................................................20-569
H-15 Travel speed is slow .............................................................................................................20-570
H-16 Travel speed does not switch ..............................................................................................20-571
H-17 Travel does not move (one side only) ................................................................................20-571
Swing system
H-18 Does not swing ......................................................................................................................20-572
H-19 Swing speed is slow or swing acceleration is poor .........................................................20-574
H-20 Swing speed is slow or swing acceleration is poor during compound
operations with arm, bucket ................................................................................................20-575
H-21 Swing speed is slow or swing acceleration is poor during compound
operations with boom RAISE when swing priority is ON ................................................20-576
H-22 Excessive overrun when stopping swing ...........................................................................20-577
H-23 Excessive shock when stopping swing ...............................................................................20-578
H-24 Excessive abnormal noise when stopping swing ..............................................................20-579
H-25 Excessive hydraulic drift of swing .......................................................................................20-580
PC750, 800-6 20-551

TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES
Hydraulic pump Control valve

Parts causing failure
Hydraulic tank and strainer
Swing compensation valve
Safety and suction valve

Swing modulation valve
Jet sensor relief valve

Straight-travel valve
Center swivel joint

Hydraulic cylinder
Jet sensor orifice
CO and NC valve
Main relief valve
Suction valve
Servo valve
TVC valve
Spool
Pump
Valve
Failure mode
All work equipment,
Speeds of all work equipment, swing, travel are slow or lack power ● ● ● ●
travel, swing
Engine speed drops or engine stalls ● ●

No work equipment, travel, swing move ● ●
Abnormal noise generated (around pump) ● ●
Auto-deceleration does not work
Boom is slow or lacks power ● ● ● ●
Arm is slow or lacks power ● ● ● ●
Bucket is slow or lacks power ● ● ● ●
Work equipment
Boom does not move ●

Arm does not move ●
Bucket does not move ●
Excessive hydraulic drift ● ● ● ●
Excessive time lag ●
Excessive shock when stopping boom (shockless switch ON)
Machine push-up function does not work properly ●
Travel deviation is excessive during compound operations ●
Machine deviates Direction of deviation is same in FORWARD and REVERSE ● ● ● ● ● ● ● ●
Travel system
naturally to one side

during travel operations Direction of deviation is different in FORWARD and REVERSE ● ●
Deviation is excessive when starting ● ● ● ● ● ●
Travel speed is slow ●
Travel speed does not switch or is faster (slower) than set speed
Does not move (one side only) ● ●
Both left and right
Does not swing
One direction only ● ●
Swing speed is slow or Both left and right
swing acceleration is poor One direction only ● ●
Swing system
Swing speed is slow or swing acceleration is poor during compound operations with arm or bucket ●
When swing priority is ON, swing speed is slow or swing acceleration is poor during compound operations with boom RAISE ●
Excessive overrun when Both left and right ●
stopping swing One direction only ●
Excessive shock when stopping swing
Excessive abnormal noise when stopping swing ●
Excessive hydraulic When swing holding brake is released ● ● ●
drift of swing When swing holding brake is applied
20-552 PC750, 800-6

●
●
●
●
Motor and leakage inside motor
● ●
● ●
● ●
● ●
Safety valve
Suction valve
● ● ● ●
● ● ●
● ●
● ●
● ●
Shuttle valve
Swing motor
●
● ●
●
●
Holding brake
PC750, 800-6
●
Back pressure compensation valve
●
●
●
Motor and leakage inside motor
Counter balance
● ● ●
●
●
TROUBLESHOOTING
Safety valve
●
Speed select servo valve
●
●
Parking brake
Pump
pump
● ●
● ●
Travel motor Control
Relief valve
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
PPC valve
●
Boom shockless valve
●
●
Swing PPC shuttle valve
●
● ●
● ●
● ●
Swing priority select valve
●
●
CO cancel
2-stage relief
●
● ● ●
Machine push-up
●
Boom shockless
●
Straight-travel
Solenoid
●
Travel speed
●
●
●
Swing holding brake
●
Swing priority
●
PTO
●
●
●
●
Swing machinery
●
●
Final drive
●
●
Engine
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-11
H-10
TABLE OF FAILURE MODES AND CAUSES
20-553
BEFORE CARRYING OUT TROUBLESHOOTING
TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC

SYSTEM (H MODE)
1. Actuation and combination of main pumps
2 piston pumps HPV95+95 are used in the
work equipment and travel circuits. The oil
from the No. 1 front pump and No. 2 front
pump merges and flows to the R.H. 4-spool
valve; and the oil from the No. 1 rear pump
and No. 2 rear pump merges and flows to
the L.H. 5-spool valve.
The No. 2 pump is controlled by the control
pressure (NC valve output pressure) from the
No. 1 pump, so it is controlled in the same
way as the No. 1 pump. If the differential
pressure of the jet sensor is defective or the
NC valve output pressure is defective, the
No. 1 front pump (rear pump) and No. 2 front
pump (rear pump) are affected at the same
time.
Therefore, if the work equipment and travel
speed is slow or lacks power, or there is
travel deviation, check using the following
procedure and the troubleshooting chart to
determine if the problem is in the pump sys-
tem (and to find which of the four pump
systems has the problem) or if the problem
is in the control valve system.
2. Judgement procedure
If the work equipment is slow and the ma- 2) If deviation is to right, No. 1 front pump
chine deviates to the left, the cause is prob- is defective
ably one of the following: 3) If the travel speed is slow on both the left
1) Drop in main relief pressure of L.H. 5- and right, the output pressure for the No.
spool control valve 1 front pump NC valve is defective or the
2) Defective jet sensor differential pressure jet sensor of the L.H. 5-spool control valve
of L.H. 5-spool control valve is defective (if the relief pressure is nor-
3) Defective NC valve output pressure for mal when both the left and right travel
No. 1 front pump are relieved).
4) Defective No. 1 front pump or No. 2 front In addition, if it is judged that the No. 1 front
pump pump or No. 2 front pump is defective and
It is possible to judge if the main relief pres- the NC valve output pressure is normal, the
sure, jet sensor differential pressure, and NC next step is to check if the defect is in the
valve output pressure are correct by measur- servo valve or in the pump itself. To make
ing the oil pressure. However, as explained this judgement, remove the servo valve and
in Item 1 above, in the case of the pumps, carry out a test on the individual part, or see
the No. 2 pump is simultaneously controlled TESTING AND ADJUSTING, Measuring servo
by the output pressure of the NC valve in- piston stroke to judge if the servo valve is
stalled to the No. 1 pump, so it is impossible defective or not.
to judge if the problem is in the No. 1 front ª When testing the servo valve as an indi-
pump or the No. 2 front pump. vidual part, carry out the test at the speci-
If the outlet port hoses of the No. 1 pump are fied maintenance work shop.
interchanged between the front and rear, it fl If the work equipment speed is slow and the
is possible to judge which pump is defective. machine deviates to the right when travel-
1) If deviation is to left, No. 2 front pump is ing, replace “front” for “rear” in the above
defective explanation.
20-554 PC750, 800-6

BEFORE CARRYING OUT TROUBLESHOOTING
TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)
Work equipment is slow or lacks

power
fl There is also travel deviation (there is no Causes
abnormality in the auto-deceleration) a b c d e f g h i j k l m n o p
1) If there is a big drop in speed and it seems L.H. 5- R.H. 4-
spool spool
No. 1 pump No. 2 pump
that there is an abnormality in the pump, control control
valve valve
check the line filter. Front Rear Front Rear
2) If there is only a small drop in speed and the pump pump pump pump
problem is not corrected by adjusting the
equipment, check the line filter.
3) To judge if the servo valve is defective or
Drop in main relief valve set pressure
Drop in main relief valve set pressure

not, remove the servo valve and carry out a
test on the individual part, or see TESTING
AND ADJUSTING, Measuring servo piston
Defective R.H. travel motor

Defective L.H. travel motor
stroke.
Defective CO, NC valve
Defective CO, NC valve

4) To check the actuation of the servo piston,
Defective servo valve
Jet sensor defective
Defective jet sensor

remove both caps and move the piston by
Defective pump
Defective pump
Defective pump
Defective pump
hand.
Troubleshooting A A A A A A
No. Remedy X X X X X X X X X X X X X X X X
1 There is travel deviation to left, and work equipment and swing speeds are slow fi fi fi fi fi fi fi
2 There is travel deviation to left, and swing speed when operated independently is particularly slow fi fi fi fi fi fi
3 There is travel deviation to left, but swing speed when operated independently is normal fi
4 There is travel deviation to right, and work equipment speed is also slow fi fi fi fi fi fi fi
5 There is travel deviation to right, and bucket DUMP speed is particularly slow fi fi fi fi fi fi
6 There is travel deviation to right, but bucket DUMP is normal fi
7 In Item 1, relief pressure is low fi
8 In Item 4, relief pressure is low fi
9 Item 7 is normal, and when No. 2 Machine deviates to left (no change) fi fi fi
10 pump outlet hoses are inter- Machine deviates to right (opposite direction) fi fi
changed between front and rear
11 Left and right travel speeds both become slow fi fi
12 In Item 11, jet sensor differential pressure is defective (L.H. 5-spool control valve) fi
13 Item 12 is normal, but front NC valve output pressure is defective fi
14 Item 8 is normal, and when No. 2 Machine deviates to right (no change) fi fi fi
15 pump outlet hoses are inter- Machine deviates to left (opposite direction) fi fi
changed between front and rear
16 Left and right travel speeds both become slow fi
17 In Item 16, jet sensor differential pressure is defective (R.H. 4-spool control valve) fi
18 Item 17 is normal, but rear NC valve output pressure is defective fi fi
19 Item 9 is normal, and No. 1 front pump servo valve is also normal fi
20 Item 10 is normal, and No. 1 front pump servo valve is also normal fi
21 Item 14 is normal, and No. 1 rear pump servo valve is also normal fi
22 Item 15 is normal, and No. 2 rear pump servo valve is also normal fi
Remedy A: Adjust X: Repair or replace
PC750, 800-6 20-555

TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)
• Method of interchanging hoses
• Hydraulic circuit diagram after interchanging hoses
20-556 PC750, 800-6

TROUBLESHOOTING H-1
H-1 Speeds of all work equipment, swing, travel are slow or lack power
fl Carry out troubleshooting in the D.H mode.
fl Check that no abnormal noise is being generated from the main pump before carrying out troubleshooting.
(If there is any abnormal noise, carry out troubleshooting for H-4.)
Cause Remedy
1
• Max. 220 mm/20 m
travel.
Is there travel deviation? NO
• Lever operated fully.
YES
Carry out troubleshooting in
—
H-13
2
• 3.33 +0.49 MPa
{34 +5.0
0
2 Is control pump relief pressure NO Carry out troubleshooting
0 kg/cm } —
• Engine at full throttle. normal? from Item 2 in H-3
YES
3
• See Table 1. Is output pressure of TVC NO
• Engine at full throttle. solenoid valve normal?
YES
• DH mode (heavy lift 4

OFF).
• Boom RAISE relief. Is main relief pressure normal NO
• 31.4 MPa at CO cancel?
{320 +10 2
–20 kg/cm }
• Engine at full throttle. YES
5 Defective engine system

• See Table 2. Is engine speed at boom NO (carry out troubleshooting in
—
• Engine at full throttle. RAISE relief normal? engine shop Manual 140-3
series)
YES
Pump body Replace
6
• See Table 3. NO
Is output pressure of CO Defective operation of CO Repair or
• Boom RAISE relief. cancel solenoid valve normal? cancel solenoid valve replace
YES
Defective main relief valve Adjust or
replace
7
Does condition become normal NO
when TVC solenoid valve is Defective TVC solenoid valve Replace
adjusted?
YES
Table 1 Defective adjustment of TVC
Adjust
solenoid valve
Control lever Min. 1.76 MPa
at neutral {18 kg/cm2} Table 3
1.18 ± 0.2 MPa Measurement
Boom RAISE relief condition Solenoid valve
{12 ± 2 kg/cm2}
output pressure
Heavy lift ON, 1.14 ± 0.2 MPa Mode Heavy lift
boom RAISE relief {11.6 ± 2 kg/cm2} DH OFF Min. 2.74 MPa {28 kg/cm2}
Table 2 DH mode DH ON Min. 2.74 MPa {28 kg/cm2}
Heavy lift OFF 1,770 ± 100 rpm H OFF 0 MPa {0 kg/cm2}
Heavy lift ON 1,770 ± 100 rpm H ON Min. 2.74 MPa {28 kg/cm2}
PC750, 800-6 20-557

TROUBLESHOOTING H-2
H-2 There is excessive drop in engine speed, or engine stalls

fl Carry out troubleshooting with engine at high idling.
1 Cause Remedy
• See Table 1. NO
Is TVC valve set pressure
• DH mode
• Engine at full throttle. normal?
YES
• At H mode relief (See 2

table 2.).
Is CO, NC valve output NO
• At DH mode [CO
cancel] (See Table 1). pressure normal at relief?
• Engine at full throttle. YES
See Engine Shop Manual —
3
• See Table 2.
Does output pressure become NO
normal when CO, NC valve is
• Engine at full throttle. adjusted?
YES
Defective adjustment of CO, Adjust
NC valve
4
• See Table 2. Does output pressure become NO
• Engine at full throttle. normal when CO, NC valves Defective CO, NC valve Replace
are cleaned?
YES
Defective operation of CO, NC Clean and
valves repair
Output pressure becomes normal, but

abnormal condition stays existing.
5
• See Table 1.
when TVC valve set pressure is
• Engine at full throttle. adjusted?
YES
Defective adjustment of TVC Adjust
valve
6
• See Table 1. Does output pressure become NO
normal when TVC valve is Defective TVC valve Replace
cleaned?
YES
Defective operation of TVC Clean and
valve repair
Output pressure becomes normal, but

abnormal condition stays existing.
20-558 PC750, 800-6

TROUBLESHOOTING H-2
Table 1 DH mode Table 2 H mode

Control levers Min. 1.76 MPa Heavy lift OFF, Min. 1.21 MPa
at neutral {18 kg/cm2} boom RAISE relief {12.3 kg/cm2}
Heavy lift OFF, 1.18 ± 0.2 MPa Heavy lift ON, 1.10 ± 0.2 MPa
boom RAISE relief {12 ± 2 kg/cm2} boom RAISE relief {11.2 ± 2 kg/cm2}
Heavy lift ON, 1.14 ± 0.2 MPa
boom RAISE relief {11.6 ± 2 kg/cm2}
PC750, 800-6 20-559

TROUBLESHOOTING H-3
H-3 No work equipment, travel, swing move

fl When auto-deceleration is normal.
fl Check operation of safety valve before starting Cause Remedy
troubleshooting. 1
When main pump pressure NO
measurement plug is Defective PTO Repair
removed, does oil come out?
YES
2
When control pump pressure NO • Defective PTO
Repair or
measurement plug is • Defective gear pump
removed, does oil come out? replace
(broken shaft, etc.)
YES
3
+0.49
• 3.33 0 MPa
+5
Is control pump relief pressure NO
{34 0 kg/cm2} normal when (1) – (4) in Fig. 1
• Engine at full throttle. is blocked?
YES Excessive leakage inside
equipment of applicable Replace
system
4
Is foreign material found in NO Defective control pump relief Adjust or
pilot filter? valve replace
YES
Defective control pump Replace
H-3 Related circuit diagram

Note: Block (1) and (9) in the diagram separately, measure the control relief pressure, and determine
the problem component. Then repair or replace.
20-560 PC750, 800-6

TROUBLESHOOTING H-4, H-5
H-4 Abnormal noise generated (around pump)
Cause Remedy
1
NO Add
Is hydraulic tank oil level
Lack of hydraulic oil hydraulic
normal?
oil
YES
Is strainer clogged? NO
YES
Clogged strainer Clean
3
Is problem removed when NO
piping between tank and pump
is tightened?
YES
Loose piping clamp Tighten
4 Inspect again
Operate for a short time and
Are metal wear particles found NO depending
watch for any change in on change in
in drained hydraulic oil? symptoms symptoms
YES
Defective pump Replace
H-5 Auto-deceleration does not work
Cause Remedy
1
Does auto-deceleration not NO
work for all levers?
YES
Go to E3, E4 —
2
Does auto-deceleration not
work only for some levers?
YES
Go to F1 - F9 —
PC750, 800-6 20-561

TROUBLESHOOTING H-6
H-6 Work equipment speed is slow (boom, arm, bucket)

fl When swing and travel are normal.
(If there is travel deviation, and the speed is slow for independent operation of the swing or bucket
DUMP, carry out troubleshooting first for H-14 Machine deviates naturally to one side during travel
operations.
a) If work equipment speed (boom, arm, bucket) is slow or lacks power in normal mode
mm/15min Cause Remedy

Boom Max. 85 ( 50) 1
Arm Max.240 (115) Is hydraulic drift of slow NO
Bucket Max.145 ( 70) cylinder within standard
The figures in ( ) show value?
the value when the work YES
equipment is not loaded.
2
• Min. 2.74 MPa
{28 kg/cm2} Is output pressure of PPC valve NO Defective operation of PPC
Replace
• Engine at full throttle. normal? valve
YES
3
• Engine at full throttle. Is actuation pressure of NO Defective operation of control Repair or
• Lever operated fully. cylinder abnormally high? valve spool replace
YES Abnormality inside hydraulic
cylinder (clogging of port, etc.) Repair
ª See TESTING AND

ADJUSTING. 4
ª It is also possible to Does speed of downward
measure leakage of NO
movement become faster
cylinder. when lever is operated?
• Max. 20 cc/min YES
• Engine at full throttle. Defective hydraulic cylinder Repair or
piston packing replace
5
Does condition become NO Defective control valve or
See Note 1. normal when safety (suction) Replace
valve is interchanged? spool
YES
Defective safety (suction)
Replace
valve
Note 1. The safety-suction valves have common mounts.

However, the settings are different for each cylinder, so be sure to replace the valves in their
original positions after completion of the troubleshooting.
ª There is a pilot hose only at the boom LOWER end.
20-562 PC750, 800-6

TROUBLESHOOTING H-6
b) If boom RAISE speed is slow or lacks power in heavy lift mode
Cause Remedy
1
• See Table 1. Is output pressure of CO NO Defective operation of CO Repair or
cancel solenoid valve normal? cancel solenoid valve replace
• Boom RAISE relief.
YES
2
• See Table 1. Is output pressure of 2-stage NO Defective operation of 2-stage Repair or
• Engine at full throttle. relief solenoid valve normal? relief solenoid valve replace
YES Defective main relief valve
(high-pressure end) of control Repair or
valve replace
Table 1
Measurement
Solenoid valve output pressure
condition
Mode Heavy lift CO cancel solenoid 2-stage relief solenoid
2
DH OFF Min. 2.74 MPa {28 kg/cm } 0 MPa {0 kg/cm2}
DH ON Min. 2.74 MPa {28 kg/cm2} Min. 2.74 MPa {28 kg/cm2}
H OFF 0 MPa {0 kg/cm2} 0 MPa {0 kg/cm2}
H ON Min. 2.74 MPa {28 kg/cm2} Min. 2.74 MPa {28 kg/cm2}
c) If boom LOWER speed is slow or lacks power when machine push-up is ON
Cause Remedy
1
Is output pressure of machine Defective operation of
• See Table . NO Repair or
push-up solenoid valve machine push-up solenoid
• Engine at full throttle. replace
normal? valve
YES Defective boom LOWER
Repair or
safety-suction valve (high-
replace
pressure end) of control valve
Table
Measurement conditions Solenoid valve output pressure
When machine push-up switch is OFF 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
When machine push-up switch is ON 0 MPa {0 kg/cm2}
PC750, 800-6 20-563

H-7 Work equipment (boom, arm, bucket) does not move (but travel
and swing are normal)
fl When boom, arm, and bucket are each operated independently.
Cause Remedy
1
• Min. 2.74 MPa
{28 kg/cm2}
Is output pressure of PPC valve NO
Defective PPC valve Replace
YES
Defective control valve spool Repair or
replace
H-8 Excessive hydraulic drift
• See TESTING AND Cause Remedy

ADJUSTING. 1
• It is also possible to
measure leakage of
Does speed of downward NO
movement become faster
cylinder. when lever is operated?
• Max. 20 cc/min
• At relief. YES
• Engine at full throttle. Defective hydraulic cylinder
seal Replace
2
Does condition become NO Defective oil-tightness
See Note 1. normal when safety-suction between control valve body Replace
valve is interchanged? and spool
YES
Defective operation of safety-
suction valve Replace
Note 1. The safety-suction valves have common mounts.

However, the settings are different for each cylinder, so be sure to replace the valves in their
original positions after completion of the troubleshooting.
ª There is a pilot hose only at the boom LOWER end.
20-564 PC750, 800-6

TROUBLESHOOTING H-9, H-10, H-11
H-9 Excessive time lag

fl When the work equipment speed is normal. (If the work equipment speed is also slow, carry out
troubleshooting first from Item 2 of H-6.)
fl Replace suction valve.
Time lag unit: sec

Boom Max. 6.0
Arm Max. 5.0
Bucket Max. 4.0
H-10 Excessive shock when boom is stopped
Cause Remedy
1
Defective operation of
Does shockless solenoid valve NO shockless solenoid valve Repair or
move normal? (valve remains open) replace
YES Defective operation of
shockless valve Repair or
(defective closing of check replace
valve)
ª Remove the solenoid valve as an individual part from the block, connect a connector, and turn the
starting switch ON. The spool is normal if it moves when the boom shockless switch is turned ON
↔ OFF.
H-11 Defective actuation of machine push-up function

fl When electrical system is normal.
Cause Remedy
1
Is output pressure of machine NO
• See Table 1. push-up solenoid valve Defective operation of Repair or
normal? solenoid valve replace
YES
Defective safety valve Replace
Table
When machine push-up switch is OFF 2.74 MPa {28 kg/cm2}
When machine push-up switch is ON 0 MPa {0 kg/cm2}
PC750, 800-6 20-565

TROUBLESHOOTING H-12
H-12 Travel deviation is excessive during compound operations

fl When independent operation of travel is normal.
fl Carry out troubleshooting in the D.H model.
Cause Remedy
1
• See Table. Is output pressure of straight NO Defective operation of straight Repair or
• Engine at full throttle. travel solenoid valve normal? travel solenoid valve replace
YES
Defective operation of straight Repair or
travel valve replace
Table 1
All work equipment control levers

0 MPa {0 kg/cm2}
at neutral
Left and right travel levers +

Min. 2.74 MPa {28 kg/cm2}
work equipment, swing control levers operated
20-566 PC750, 800-6

H-13 Machine deviates naturally to one side during travel operations

fl When travel speed is normal.
a) Direction of deviation is same in FORWARD and REVERSE
Cause Remedy
1
Was it possible to locate NO
abnormality in troubleshooting
chart on page 20 – 555
YES Adjust,
See cause column in
repair, or
troubleshooting chart
replace
2
• Min. 2.74 MPa Is output pressure of PPC valve NO
{28 kg/cm2} Defective PPC valve Replace
normal?
YES
3
• Max. 40¬/min NO
(one side)
Is amount of oil drained from Excessive leakage inside
travel motor normal? motor Replace
YES
4
Are metal particles found in oil NO
drained from final drive on
side of deviation?
YES
Defective inside final drive Repair or
replace
5
ª See TESTING AND Does condition return to normal NO
ADJUSTING.
when travel deviation is adjusted
according to specified procedure?
YES
Defective adjustment of pump Adjust
6
• Max. 100 cc/min
• Engine at full throttle. Is leakage from swivel joint NO
• See TESTING AND Defective swivel joint packing Repair
packing normal?
ADJUSTING.
YES
7
Does direction of deviation change NO Repair or
when hoses between swivel joint Defective travel motor
and motor are interchanged? replace
YES
Defective control valve Replace
PC750, 800-6 20-567

b) Direction of deviation is different in FORWARD and REVERSE
Cause Remedy
1
NO
Is deviation as shown in Fig. 1?
YES
Defective swivel joint packing Repair
• 32.4 +1.0
–2.0 MPa 2
2
{330+10
–20 kg/cm } NO
Is relief pressure at travel Drop in set pressure of travel Adjust
• DH mode motor relief normal? motor safety valve
• Each side relief. YES
3
• Min. 2.74 MPa
Is output pressure of PPC valve NO
{28 kg/cm2} Defective PPC valve Replace
YES
Defective operation of control Replace
valve spool
Fig. 1
1 Forward Location of defective swivel joint

packing and direction of travel deviation
Forward 4
T port
(drain)
Reverse
A port
(L.H. FORWARD)
2 Forward Reverse
B port
(L.H. REVERSE)
Forward 5
P port
(SPEED CHANGE)
Reverse
C port
3 (R.H. FORWARD) Reverse
Forward
D port
(R.H. REVERSE) Forward 6
Lower side
Reverse
Reverse
20-568 PC750, 800-6

H-14 Deviation is excessive when starting

fl When travel speed is normal.
fl If there is also deviation during travel, see H-13 Machine deviates naturally to one side during
travel operations.
If there is deviation during compound operations with the work equipment, carry out troubleshoot-
ing first for H-12 Travel deviation excessive during compound operations.
fl Bleed the air from the circuit before the operation.
Cause Remedy
1
• Max. 220 mm/20 m
travel. Is there deviation when lever is NO
• Engine at full throttle. operated fully?
YES
2
Is direction of deviation reversed NO
when pump outlet hoses are
interchanged between front and rear?
YES
Defective operation of servo Replace
valve
3
Is direction of deviation reversed NO Defective travel motor (motor, Replace
when hoses are interchanged at
swivel outlet port? safety valve, brake)
YES
4
when hoses are interchanged at Defective swivel joint Repair or
swivel inlet port? replace
YES
Defective operation of control Replace
valve spool
5
Is there deviation when lever is
operated fully or when lever is
operated a small amount?
YES
6
Is differential pressure normal NO
for jet sensor on fast side
(outside of turn)?
YES
• Control lever at
neutral: Max. 0.55 MPa 7
{5.5 kg/cm2} Is output pressure of CO, NC NO
• Track rotated under no
load: Min. 1.67 MPa valve normal on fast side?
{17 kg/cm2} YES
• Engine at full throttle. Defective operation of servo Replace
valve
8
• See Table. Does output pressure become NO
normal when CO, NC valve is Defective CO, NC valve Repair or
• Engine at full throttle. replace
adjusted?
YES
Defective adjustment of CO,
Repair
NC valve
Go to Item 9 on next page
PC750, 800-6 20-569

From Item 3 on previous page

Cause Remedy
9
when jet sensor relief valves are
interchanged or adjusted?
YES
Defective control valve jet Repair or
sensor relief valve replace
10
• See Table. Does differential pressure become NO
normal when relief valves are Defective control valve jet Repair or
• Engine at full throttle. sensor orifice replace
interchanged on opposite sides?
YES
Defective control valve jet Repair or
sensor orifice replace
Table
Measurement conditions Jet sensor differential pressure CO, NC valve output pressure
All work equipment control levers

Min. 1.14 MPa {11.6 kg/cm2} Max. 0.55 MPa {5.5 kg/cm2}
at neutral
Travel lever operated fully

Max. 0.15 MPa {1.5 kg/cm2} Min. 1.67 MPa {17 kg/cm2}
(track rotating under no load)
H-15 Travel speed is slow

fl When there is no travel deviation.
ª If main relief pressure has dropped, the work equipment will lack power even during normal
operations.
Cause Remedy
1
• Min. 2.74 MPa
{28 kg/cm2}
Is output pressure of PPC valve NO Defective PPC valve Replace
YES
2
• Min. 2.74 MPa Is outlet pressure of CO cancel NO
{28 kg/cm2} Defective operation of CO Repair or
solenoid valve normal? cancel solenoid valve replace
YES
Drop in main relief pressure Adjust
20-570 PC750, 800-6

H-16 Travel speed does not switch

fl When travel speed is normal in Hi or Lo.
ª If the fuel control dial is set to 1,400 rpm or below, the speed is fixed in Lo.
Cause Remedy
• At Hi: 1
Min. 2.74 MPa
{28 kg/cm2} Is oil pressure at travel speed NO Defective travel speed
• At Lo: solenoid outlet port normal? solenoid valve Replace
0 MPa {0 kg/cm2}
• Engine at full throttle. YES Replace
Defective travel motor motor
• Speed selector servo valve assembly
H-17 Travel does not move (one side only)

Cause Remedy
1
Is any foreign material found NO
in oil drained from final drive?
YES
Repair or
Defective final drive replace
2
• Min. 2.74 MPa NO Repair or
{28 kg/cm2} Is PPC valve output pressure Defective PPC valve
• Engine at full throttle. normal? replace
YES
• 32.4 +1.0
–2.0 MPa
3
2
{330+10
–20 kg/cm } Is travel relief valve pressure NO
• Eegine at full throttle.
• Relieve circuitr on one
normal?
side. YES Defective travel motor (motor
Repair or
itself or counterbalance valve)
replace
or brake dragging
4
Is problem reversed when safety NO
valves are interchanged on
motors on opposite sides?
YES
Defective travel motor safety Repair or
valve replace
5
Is condition reversed when NO Defective operation of control Repair or
suction valves interchanged on
opposite sides? valve spool replace
YES
Defective control valve Repair or
suction valve replace
PC750, 800-6 20-571

H-18 Does not swing

fl When other work equipment and travel are normal.
fl Turn the swing lock switch OFF.
fl Before starting troubleshooting, check that there is no clogging of the throttle in the elbow
installed to the PPC port (PA2, PB2) of the L.H. 5-spool control valve. If there is clogging, clean and
check that the condition has returned to normal.
Cause Remedy
1
• Min. 2.74 MPa
{28 kg/cm2} Is output pressure of PPC valve NO
• Engine at full throttle. (both left and right) normal?
• Operate lever fully.
YES
2
Are both left and right
abnormal or one side only
abnormal?
YES
3
Does condition return to NO Repair or
normal when swing PPC Defective PPC valve
shuttle valve is bypassed? replace
YES
Defective swing PPC shuttle Repair or
valve replace
4
Is problem with swing in both NO
left and right directions or in
one direction only?
YES
5
• Min. 2.74 MPa Is output pressure of swing NO Defective swing brake Repair or
{28 kg/cm2} brake solenoid valve normal? solenoid valve replace
YES
6
Is any foreign material found Defective swing motor brake
• Check both front and NO Repair or
rear separately. in oil drained from swing or defective swing motor or
machinery? shuttle valve replace
YES
Repair or
Defective swing machinery replace
7
Is problem with swing in one
direction only?
YES
8
Is problem reversed when left NO
and right suction valves of
travel motor are interchanged?
YES Defective swing motor suction Repair or
valve replace
9
• Check both front and Is problem reversed when NO
rear separately. direction of swing motor
suction valves is reversed?
YES Defective swing motor shuttle Repair or
valve replace
Go to Item 10 on next page
20-572 PC750, 800-6

From Item 9 on previous page

Cause Remedy
10
control valve are interchanged?
YES Defective control valve Repair or
suction valve replace
11
Does control valve spool move NO Defective operation of control Repair or
smoothly? valve spool replace
YES
Defective swing motor Repair or
replace
PC750, 800-6 20-573

H-19 Swing speed is slow or swing acceleration is poor

fl When other work equipment and travel are normal.
(However, if there is travel deviation (deviation to left), carry out troubleshooting first for H-13
Machine deviates naturally to one side during travel operations. )
1 Cause Remedy
Does condition become NO
normal when swing priority is
turned ON.
YES Defective PPC valve (boom Repair or
RAISE) replace
2
when port P of swing priority
selector valve is blocked?
YES Defective swing priority Repair or
selector valve replace
3
• Min. 2.74 MPa
{28 kg/cm2}
Is output pressure of swing NO
PPC valve normal on both left
• Engine at full throttle. and right?
YES
4
Is swing speed slow in both NO
directions?
YES
5
• 10 ¬/min
• Engine at full throttle. Is drain amount from swing NO Excessive leakage inside Repair or
• Check front and rear motor normal? swing motor replace
separately.
YES
6
Is any foreign material found Defective swing motor brake
• Check both front and NO Repair or
in oil drained from swing or defective swing motor or
rear separately.
machinery? replace
shuttle valve
YES
Repair or
Defective swing machinery
replace
7
Is swing speed slow in one
direction only?
• Check front and rear
separately. YES
8
ª It is also possible to
measure the oil
pressure. swing motor are interchanged?
• 28.4 +2.5
–0.5 MPa
{290 +25 2 YES Defective swing motor suction Repair or
–5 kg/cm }
• Engine at full throttle. valve replace
9
• Check both front and Is problem reversed when NO
rear separately. direciton of swing motor
shuttle valves is reversed?
YES Defective swing motor shuttle Repair or
valve replace
Go to Item 12 Go to Item 10
on next page on next page
20-574 PC750, 800-6
From Item 3 From Item 9

on previous page on previous page
Cause Remedy
10
YES Defective control valve shuttle Repair or
valve replace
11
Does control valve spool move NO Defective operation of control Repair or
smoothly? valve spool replace
YES
Defective swing motor Repair or
replace
12
Does condition return to NO Repair or
normal when swing PPC Defective PPC valve (swing)
shuttle valve is bypassed? replace
YES
Defective swing PPC shuttle Repair or
valve replace
H-20 Swing speed is slow or swing acceleration is poor during

compound operations with arm, bucket
fl When independent operation is normal.
Cause Remedy
1
Does condition become normal when NO
port A2 hose and port P hose of swing
priority selector valve are bypassed?
YES
Defective swing priority Repair or
2
• Min. 2.35 MPa
{24 kg/cm2} Is pressure at port P3 of swing NO Defective swing PPC shuttle Repair or
• Engine at full throttle. PPC shuttle valve normal? valve replace
• Operate lever fully.
YES Defective swing
compensation valve of control Repair or
valve replace
PC750, 800-6 20-575

H-21 Swing speed is slow or swing acceleration is poor during

compound operations with boom RAISE when swing priority is
ON
fl When independent operation is normal.
Cause Remedy
1
Does condition become normal when NO
port A2 hose and port P hose of swing
priority selector valve are bypassed?
YES
Defective swing priority Repair or
2
Is output pressure of swing NO Defective swing priority Repair or
priority solenoid valve normal? solenoid valve replace
YES
Defective swing throttle valve Repair or
of control valve replace
When swing priority is OFF Min. 2.35 MPa {24 kg/cm2}
When swing priority is ON 0 MPa {0 kg/cm2}
20-576 PC750, 800-6

H-22 Excessive overrun when stopping swing

Cause Remedy
1
Is swing speed slow in both NO
left and right directions?
YES
2
• 10 ¬/min
• Engine at full throttle. Is drain amount from swing NO Excessive leakage inside Repair or
• Check front and rear motor normal? swing motor replace
separately.
YES
Defective swing motor safety Repair or
valve or defective motor replace
3
swing motor are interchanged?
YES
Defective swing motor suction Repair or
valve replace
4
• 28.4 +2.5
–0.5 MPa
{290 +25 2 Is problem reversed when NO
–5 kg/cm } direction of swing motor
• Check both front and
rear separately.
YES
Defective swing motor shuttle Repair or
valve replace
5
YES
Defective suction valve of Repair or
control valve replace
6
Does control valve spool move NO Defective operation of swing Repair or
smoothly? spool of control valve replace
YES
7
Is problem reversed when left NO Repair or
and right output hoses of PPC Defective swing motor
valve are interchanged? replace
YES
Repair or
Defective PPC valve
replace
PC750, 800-6 20-577

H-23 Excessive shock when stopping swing

fl When swing speed is normal.
Cause Remedy
1
Is shock excessive in both left NO
and right directions?
YES
2
Is oil pressure at swing brake NO Defective swing brake
• See Table. solenoid valve outlet port Replace
normal? solenoid valve
YES
3
Is foreign material found in oil NO
drained from swing Defective swing motor brake Replace
machinery?
YES
Defective swing machinery Repair
4
Is problem reversed when NO Repair or
direction of swing motor Defective swing motor replace
YES
valve replace
Table
Measurement conditions Solenoid valve outlet pressure
10 sec. after returning swing control lever to neutral 0 MPa {0 kg/cm2}
Swing control lever operated Min. 2.74 MPa {28 kg/cm2}
20-578 PC750, 800-6

H-24 Excessive abnormal noise when stopping swing
Cause Remedy
1
Bleed air according to Section 3-3) of
TESTING AND ADJUSTING, Bleeding air
NO
from all parts. Is abnormal noise reduced?
YES Bleed air (see
Air inside swing motor safety TESTING
valve drain case AND
ADJUSTING)
2
when swing motor safety-
suction valve is cleaned?
YES Defective operation of swing
motor safety valve, suction Clean
valve, shuttle valve
3
when swing motor safety-
suction valve is replaced?
YES Defective swing motor safety
valve, suction valve, shuttle Replace
valve
4
when safety-suction valve of
control valve is cleaned?
YES
Defective operation of suction Clean
valve of control valve
5
when safety-suction valve of
control valve is replaced?
YES
Defective suction valve of Replace
control valve
6
Is foreign material found in NO Clean or
swing machinery? Defective back pressure valve
replace
YES
Repair or
Defective swing machinery
replace
PC750, 800-6 20-579

H-25 Excessive hydraulic drift of swing

a) When swing holding brake is released
Cause Remedy
1
Is hydraulic drift excessive in NO
one direction only?
YES
2
and right swing motor suction
valves are interchanged?
YES
Defective swing motor suction Repair or
valve replace
3
Is problem reversed when NO
direction of swing motor
YES
valve replace
4
Is problem reversed when left NO • Defective control valve or Repair or
and right suction valves are
interchanged? • Defective swing motor replace
YES
Defective suction valve of Repair or
control valve replace
• 28.4 +2.5
–0.5 MPa
5
{290 +25 kg/cm2} Is swing relief pressure NO
–5 Defective swing motor safety Repair or
• DH mode
normal? valve replace
• Operate lever fully. YES
6
• 10 ¬/min NO Excessive leakage inside
Is drain amount from swing Repair or
• At swing relief. motor normal? swing motor replace
YES
Defective oil tightness of Repair or
control valve spool replace
b) When swing holding brake is applied

Cause Remedy
1
• See Table. Is output pressure of swing NO Defective operation of swing Repair or
• Engin at full throttle. holding brake solenoid valve
normal? holding brake solenoid valve replace
YES
Defective operation of swing Correct or
holding brake replace
Table
Measurement conditions Solenoid valve outlet pressure
10 sec. after returning swing control lever to neutral 0 MPa {0 kg/cm2}
Swing control lever operated Min. 2.74 MPa {28 kg/cm2}
20-580 PC750, 800-6

TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
(M MODE)
Action taken by monitor panel when abnormality occurs and problems on machine ..................20-602
Electrical circuit diagram for M mode system ....................................................................................20-604
M-1 [E101] (Abnormality in error data) or [E102] (Abnormality in clock data)
is displayed...............................................................................................................................20-606
M-2 [E103] (Short circuit in buzzer output system) is displayed ...............................................20-607
M-3 [E104] (Air cleaner clogging detection) is displayed ...........................................................20-608
M-4 [E108] (Engine water temperature 105°C) is displayed .......................................................20-608
M-5 When starting switch is turned ON, none of lamps on monitor panel light up
for 3 seconds ............................................................................................................................20-609
M-6 When starting switch is turned ON, monitor panel lamps all stay lighted up
and do not go out ...................................................................................................................20-611
M-7 When starting switch is turned ON, items lighted up on monitor panel are
different from actual machine ................................................................................................20-611
M-8 When starting switch is turned ON (engine stopped), basic check items flash .............. 20-612
M-9 Preheating is not being used but preheating display motor lamp lights up ...................20-615
M-10 When engine is started, basic check items flash .................................................................20-616
M-11 When starting switch is turned ON (engine stopped), CAUTION items and
EMERGENCY STOP items flash .............................................................................................20-617
M-12 When engine is started, CAUTION items and EMERGENCY STOP items flash .............. 20-618
M-13 Operation of alarm buzzer is not normal .............................................................................20-622
M-14 Night lighting on monitor panel does not light up .............................................................20-624
M-15 Engine water temperature display is not normal ................................................................20-625
M-16 Fuel level gauge display is not normal .................................................................................20-626
M-17 Swing lock switch is turned ON but swing lock monitor lamp
does not light up .....................................................................................................................20-628
M-18 When swing brake release switch is set to RELEASE (EMERGENCY),
swing lock monitor lamp does not flash ..............................................................................20-629
M-19 Service meter does not give normal display .......................................................................20-630
M-20 Defective fuel level sensor system ........................................................................................20-631
M-21 Defective engine oil level sensor system .............................................................................20-632
M-22 Defective coolant level sensor system ..................................................................................20-633
M-23 Defective hydraulic oil level sensor system .........................................................................20-634
M-24 Wiper is not actuated when wiper switch is operated or wiper is actuated
when wiper switch is not operated .......................................................................................20-635
M-25 Window washer is not actuated when wiper switch is operated or
window washer is actuated when switch is not operated .................................................20-640
M-26 Electric grease gun does not work (machines equipped with electric
grease gun)...............................................................................................................................20-643
PC750, 800-6 20-601

ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY

User Service
code code
1. Abnormality in internal memory
2. Excess voltage (more than 36V) has occurred
3. Low voltage (less than 12V) has occurred
Abnormality in error 4. Defective connection of connector
— E101 data
1. Abnormality in internal clock function

2. Excess voltage (more than 36V) has occurred
3. Low voltage (less than 12V) has occurred
— E102 Abnormality in clock 4. Defective connection of connector
data
1. Short circuit inside buzzer

2. Short circuit with power source in wiring harness between monitor
— E103 Short circuit in buzzer panel P01 (7) and alarm buzzer P04 (2)
output system 3. Defective monitor panel
fl If there is a disconnection, [E103] is not displayed and the buzzer
does not sound.
1. Air cleaner clogging sensor has detected clogging

— Air cleaner clogging
E104 detection
1. Engine water temperature sensor has detected water temperature

Engine water of 105°C pressure
— E108 temperature 105˚C
detection
1. Short circuit or short circuit with ground inside wiper motor

Short circuit in wiper 2. Short circuit or short circuit with ground inside relay box
— E112 drive normal rotation 3. Short circuit or short circuit with ground in wiring harness be-
system tween monitor panel P02 (11) and relay box W08 (17), or between
relay box W08 (7) and wiper motor W04 (3)
1. Short circuit or short circuit with ground inside wiper motor

Short circuit in wiper 2. Short circuit or short circuit with ground inside relay box
— E113 drive reverse rotation 3. Short circuit or short circuit with ground in wiring harness be-
system tween monitor panel P02 (3) and relay box W08 (18), or between
relay box W08 (6) and wiper motor W04 (1)
Short circuit in win- 1. Short circuit inside washer motor

— E114 dow washer drive 2. Short circuit with power source in wiring harness between monitor
system panel P02 (2)(10) and washer motor M28 (1)
20-602 PC750, 800-6

Action by controller when Problem that appears on machine

Condition when normal
abnormality is detected when there is abnormality
• When starting switch is 1. Service code cannot be cleared
OFF, press time switch. 2. Time becomes 00:00.
Keep pressed, turn
starting switch ON, and
keep time switch pressed
for at least another 5
seconds to reset (if it is
reset, it is normal)
• When starting switch is 1. Service code cannot be cleared

OFF, press time switch. 2. Time becomes 00:00.
Keep pressed, turn 3. Clock does not advance.
starting switch ON, and
keep time switch pressed
for at least another 5
seconds to reset (if it is
reset, it is normal).
• Voltage between P01 (7) 1. Buzzer does not sound

and ground
Buzzer ON: Max. 1V
Buzzer OFF: 20 – 30V
• Resistance between P11 1. If this is continuously detected,

(male) and P12 (female) air cleaner clogging caution
When engine is running: lamp flashes and alarm buzzer
Max. 1 Ω sounds
• See section on Engine 1. Engine water temperature cau-

controller tion lamp flashes and alarm
buzzer sounds
2. Overheat prevention function is
actuated and engine speed is set
to low idling
• Voltage between W04 (3) 1. Sets output to relay box to 0 1. Wiper operation stops
and (5) :
More than 3 V ↔ 20 – 30 V
fl Repeated in a constant
cycle
• Voltage between W04 (1) 1. Sets output to relay box to 0 1. Wiper operation stops
and (5) :
More than 3 V ↔ 20 – 30 V
fl Repeated in a constant
cycle
• Resistance between P02 1. Sets output to washer motor to 0 1. Window washer operation stops
(2)(10) and W08 (15): Max.
1Ω
PC750, 800-6 20-603

TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
20-604 PC750, 800-6

TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
PC750, 800-6 20-605

TROUBLESHOOTING M-1
M-1 [E101] (Abnormality in error data) or [E102] (Abnormality in clock

data) is displayed
fl When the connector is disconnected to carry out troubleshooting and this temporarily shuts off the
power supply to the monitor panel, a service code is displayed, but this is not an abnormality.
Cause Remedy
• See Note 1.
1
• Operate for a short After reset operation is carried NO
out, is service code displayed Normal —
time and watch for any
again?
change in symptoms.
YES
2
• Turn starting switch Is voltage between P02 (8) (14) NO
OFF. and ground 20 – 30 V?
YES
• Turn starting switch disconnection in wiring Repair or
Is voltage between B19 and NO
OFF. harness between battery relay replace
ground 20 – 30 V?
• Disconnect B19. terminal B and B19
YES
Defective contact or Repair or
disconnection in wiring replace
harness between P02 (female)
(8) (14) and B29
Note 1: Reset operation:

With the starting switch OFF, press the time switch, keep it pressed and turn the starting
switch ON, then keep the time switch pressed for at least another 5 seconds.
M-1 Related electrical circuit diagram
20-606 PC750, 800-6

TROUBLESHOOTING M-2
M-2 [E103] (Short circuit in buzzer output system) is displayed
Cause Remedy
1
• Turn starting switch Is resistance between P04 NO
OFF. (male) (1) – (2), and between (2) Defective alarm buzzer Replace
• Disconnect P04. – ground as shown in Table 1?
YES
source in wiring harness
2 between P01 (female) (7) and
Repair or
Is voltage between P04 (2) and NO P04 (female) (2) or short
replace
ground as shown in Table 1? circuit in wiring harness
between P04 (1) and (2)
YES
Table 1
P04 (male) Resistance value
Between (1) and (2) 200 – 300 Ω
PC750, 800-6 20-607

TROUBLESHOOTING M-3, M-4
M-3 [E104] (Air cleaner clogging detection) is displayed
Cause Remedy
1
Is air cleaner clogging caution NO
lamp on monitor panel
flashing?
YES
Go to M-12 f) —
2
Is [E] displayed at head of NO Defective air cleaner —
service code? (See Note 1)
YES
Note 1: The monitor panel display has been reset, but in the past, the air cleaner clogging sensor has
detected clogging, so clean the air cleaner thoroughly. For details, see the Operation and
Maintenance Manual.
M-4 [E108] (Engine water temperature 105°C) is displayed
Cause Remedy
1
Does water temperature on NO
monitor panel display red range,
and is caution lamp flashing?
YES
Go to M-12 d) —
2
Is [E] displayed at head of NO Failure in engine (See Note 1) —
service code?
YES
Note 1: The monitor panel display has been reset, but in the past, the engine water temperature
sensor has detected a water temperature of 105°C, so carry out troubleshooting of the engine
to locate the cause and remove the problem.
20-608 PC750, 800-6

TROUBLESHOOTING M-5
M-5 When starting switch is turned ON, none of lamps on monitor

panel light up for 3 seconds
fl Check that the engine starts normally. (If it does not start, carry out troubleshooting for E Mode
first.)
fl Before carrying out troubleshooting, check that circuit breakers 9 and 10 have not shut off the
circuit, and that fuse 10 is not blown. (If the breaker has shut off the circuit or the fuse is blown,
there has probably been a surge of current caused by a short circuit with the ground, so check the
circuits related to circuit breakers 9 and 10 and fuse 10.)
a) None of lamps on monitor panel light up
Cause Remedy
1
Is voltage between P02 (8) (14) NO
and ground 20 – 30 V?
YES
Defective contact,
2 Repair or
between P02 (female) (8) (14)
Is resistance between P02 (1) NO replace
OFF. and battery relay terminal B,
• Disconnect P02. (9) and ground less than 1 Ω? or defective circuit breaker 9
harness between P02 (female) replace
(1) (9) and ground
3
Is voltage between P01 (9) and NO
ground 20 – 30 V?
YES
Defective contact,
4 with ground in wiring harness
between fuse 10 inlet and Repair or
Is voltage between fuse 10 NO replace
• Turn starting switch ON. battery relay terminal M, or
inlet and ground 20 – 30 V?
defective circuit breaker 1
disconnection, or short circuit Repair or
between P01 (female) (9) and
fuse 10
b) Some of lamps on monitor panel do not light up

fl Replace monitor panel
PC750, 800-6 20-609

TROUBLESHOOTING M-5
20-610 PC750, 800-6

TROUBLESHOOTING M-6, M-7
M-6 When starting switch is turned ON, monitor panel lamps all stay
lighted up and do not go out
fl Replace monitor panel
M-7 When starting switch is turned ON, items lighted up on monitor

panel are different from actual machine
fl If this problem occurs immediately after the monitor panel has been replaced, turn the starting
switch OFF, then turn it ON and check again.
Cause Remedy
1
• Turn starting switch ON. Is display of monitoring code NO
• Set monitoring code to Defective monitor panel Replace
[01] as shown in Table 1?
[01].
YES
Go to troubleshooting C-16
Replace
(error code [E217] displayed)
Table 1
Monitoring code Detail of display
01 Monitor panel model code
PC750, 800-6 20-611

TROUBLESHOOTING M-8
M-8 When starting switch is turned ON (engine stopped), basic check

items flash
a) Radiator coolant level caution lamp flashes
fl Check that the coolant is at the specified level before carrying out troubleshooting.
Cause Remedy
• Disconnect P08, P20. 1
• Turn starting switch ON. Does display go out when NO
• Check P08 and P20 short connector is connected
individually.
to P08, P20 (female)?
YES Defective radiator coolant
level sensor system —
(go to M-22)
2
OFF. (female) (2) and ground less
• Disconnect P20. than 1 Ω?
YES
• Turn starting switch Is resistance between C16 NO disconnection in wiring Repair or
OFF. (female) (8) and ground as
• Disconnect C16. shown in Table 1? harness between C16 (female) replace
YES (8) and P20 (female) (1)
4
Is bit (3) of monitoring code NO
[24]. [24] lighted up?
YES
• Turn starting switch Is resistance between P08 NO disconnection in wiring Repair or
OFF. (female) (2) and ground less harness between P08 (female) replace
• Disconnect P08. than 1 Ω? (2) and ground
YES
Table 1 disconnection in wiring Repair or
P20 (female) (1) and ground Resistance value
(2) and P08 (female) (1)
Connected Max. 1 Ω
Disconnected Min. 1 MΩ
M-8 a) Related electrical circuit diagram
20-612 PC750, 800-6

TROUBLESHOOTING M-8
b) Engine oil level caution lamp flashes

fl Check that the engine oil is at the specified level before carrying out troubleshooting.
Cause Remedy
1
• Disconnect OL. Does display go out when OL NO
• Turn starting switch ON. (female) (1) is connected to
ground?
YES
Defective engine oil level
Replace
sensor system (go to M-21)
• Turn starting switch Is resistance between C16
OFF. NO disconnection in wiring Repair or
(female) (16) and ground as
• Disconnect C16 and shown in Table 1? harness between C16 (female) replace
OL. YES (16) and OL (female) (1)
3
• Turn starting switch ON. NO
Is bit (4) of monitoring code Defective monitor panel Replace
• Set monitoring code to
YES
Table 1
OL (female) (1) and ground Resistance value
M-8 b) Related electrical circuit diagram
PC750, 800-6 20-613

TROUBLESHOOTING M-8
c) Hydraulic oil level caution lamp flashes

fl Check that the hydraulic oil is at the specified level before carrying out troubleshooting.
Cause Remedy
1
• Disconnect P09. Does display go out when P09 NO
• Turn starting switch ON. (female) (1) is connected to
ground?
YES
Defective hydraulic oil level
Replace
sensor system (go to M-23)
P09. YES (9) and P09 (female) (1)
3
• Turn starting switch ON. NO
Is bit (5) of monitoring code Defective monitor panel Replace
YES
Table 1
P09 (female) (1) and ground Resistance value
M-8 c) Related electrical circuit diagram
20-614 PC750, 800-6

TROUBLESHOOTING M-9
M-9 Preheating is not being used but preheating display motor lamp
lights up
Cause Remedy
1
• Disconnect starting Is voltage between starting NO
switch R1. switch terminal R1 and ground Defective starting switch Replace
• Turn starting switch ON. less than 1 V?
YES

2 source in wiring harness
Is voltage between P01 (18) NO between starting switch Repair or
and ground less than 1 V? terminal R1 – P01 (female) (18) replace
– heater relay HT
YES
PC750, 800-6 20-615

TROUBLESHOOTING M-10
M-10 When engine is started, basic check items flash
Cause Remedy
1
Is service code [E924] or [E936] NO
displayed at same time?
YES Carry out troubleshooting for
displayed service code —
(go to E Mode)
2
• Run engine at a mid- Is voltage between alternator NO Defective alternator Replace
range speed. terminal R and ground 20 – 30 V?
YES
• Run engine at a mid- Is voltage between C03 (12) NO with ground in wiring harness Repair or
range speed. and ground 20 – 30 V? between C03 (female) (12) and replace
YES alternator terminal R
4
• Run engine at a mid- Is more than 100 displayed for NO
range speed. alternator input voltage for Defective monitor panel Replace
• Set monitoring code to monitoring code [43]?
[43]. YES
20-616 PC750, 800-6

M-11 When starting switch is turned ON (engine stopped), CAUTION

items and EMERGENCY STOP items flash
Cause Remedy
1
• Turn starting switch ON. displayed at same time?
(go to E Mode)
2
• Run engine at a mid-
Is voltage between alternator NO
terminal R and ground less Defective alternator Replace
range speed. than 1 V?
YES

• Run engine at a mid- Is voltage between C03 (12) NO source in wiring harness Repair or
range speed. and ground less than 1 V? between C03 (female) (12) and replace
alternator terminal R
YES
4
• Run engine at a mid- Is more than 100 displayed for NO
range speed. alternator input voltage for Defective monitor panel Replace
[43]. YES
PC750, 800-6 20-617

M-12 When engine is started, CAUTION items and EMERGENCY STOP

items flash
a) Engine oil pressure caution lamp flashes
fl Check that the engine oil pressure is normal before carrying out troubleshooting.
Cause Remedy
1
• Turn starting switch ON. Defective monitor panel Replace
(go to E Mode)
b) Radiator coolant level caution lamp flashes

fl Check that the radiator coolant level is at the specified level before carrying out troubleshoot-
ing.
fl Carry out troubleshooting for M-8.
c) Charge caution lamp flashes

fl Carry out troubleshooting for M-10.
20-618 PC750, 800-6

d) Engine water temperature caution lamp flashes

fl Check that the engine water temperature is normal before carrying out troubleshooting.
Cause Remedy
1
Is service code [E934] NO
(go to E Mode)
e) Fuel level caution lamp flashes

fl Check that there is enough fuel before carrying out troubleshooting.
Cause Remedy
1
Does fuel gauge show E range NO
• Start engine. Defective monitor panel Replace
(left end)?
YES
2
• Disconnect P06. When P06 (female) (1) is connected NO
to ground, does fuel gauge display
show F range (right end)?
YES
Defective fuel level sensor
system (go to M-20) —

• Disconnect C03. Is voltage between C03 NO source in wiring harness Repair or
(female) (2) and ground less between C03 (female) (2) and replace
than 1 V?
P06 (female) (1)
YES
M-12 e) Related electrical circuit diagram
PC750, 800-6 20-619

f) Air cleaner clogging caution lamp flashes

fl Check that the air cleaner is not clogged before carrying out troubleshooting.
Cause Remedy
1
• Disconnect P11.
When P11 (female) (1) and (2) NO
are connected, does display
• Start engine. disappear?
YES
Defective air cleaner clogging
Replace
sensor
• Disconnect P11. Is resistance between P11 NO disconnection in wiring Repair or
• Turn starting switch (female) (2) and ground less
OFF. than 1 Ω? harness between P11 (female) replace
(2) and ground
YES
P11. (17) and P11 (female) (1)
YES
4
• Turn starting switch ON. Is bit (6) of monitoring code NO
[24].
[24] lighted up?
YES
Table 1
P11 (female) (1) and (2) Resistance value
M-12 f) Related electrical circuit diagram
20-620 PC750, 800-6

g) Hydraulic oil temperature caution lamp flashes

fl Check that the hydraulic oil temperature is normal before carrying out troubleshooting
Cause Remedy
1
• Disconnect P10. When P10 is disconnected, NO
• Start engine. does display disappear?
YES Defective hydraulic oil
temperature sensor system Replace
(go to M-23)
Short circuit with ground in
2
• Turn starting switch wiring harness between C03
Is resistance between C03 (female) NO
OFF. (11) and (16), between (11)(16) and (female) (11) and P10 (female) Repair or
• Disconnect C03 and ground more than 1 MΩ? (1) or defective contact with replace
P10. YES wiring harness between C03
(female) (16) and P10 (female)
(2)
3
• Turn starting switch ON. Is more than 21 displayed for hydraulic NO
• Set monitoring code to oil temperature sensor input voltage of Defective monitor panel Replace
[44]. monitoring code [44]?
YES
M-12 g) Related electrical circuit diagram
PC750, 800-6 20-621

M-13 Operation of alarm buzzer is not normal

a) When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second.
Caution item is flashing, but alarm buzzer does not sound.
fl Of the caution items, the buzzer will not sound even if the lamp lights up for the battery charge
or fuel level.
Cause Remedy
1
Is resistance between P04 NO
OFF. Defective alarm buzzer Replace
• Disconnect P04. (male) (1) and (2) 3 – 4 MΩ?
YES
2
• Disconnect P01. When P01 (female) (7) is NO
• Turn starting switch ON. connected to ground, does
buzzer sound?
YES
3
Is voltage between P04 (1) and NO between battery relay terminal Repair or
ground 20 – 30 V? B and P04 (female) (1) replace
(7) and P04 (female) (2)
b) No abnormality is displayed on monitor but buzzer sounds

fl If the buzzer sounds continuously, carry out this troubleshooting. (If it sounds intermittently,
carry out troubleshooting for a).)
Cause Remedy
1
OFF. (male) (2) and ground more Defective alarm buzzer Replace
• Disconnect P04. than 1 MΩ?
YES

• Disconnect P01. When P01 is disconnected, NO wiring harness between P01 Repair or
• Turn starting switch ON. does buzzer stop? (female) (7) and P04 (female) replace
(2)
YES
20-622 PC750, 800-6

PC750, 800-6 20-623

M-14 Night lighting on monitor panel does not light up

fl Check that front lamps and working lamp light up before carrying out troubleshooting.
Cause Remedy
1
• Remove bulb. Is bulb blown, or is there NO
• Check bulb visually. defective contact?
YES
Blown bulb or defective
Replace
contact

2
• Set monitoring code to Is bit (3) of monitoring code NO
[49]. [49] out?
• Turn light switch ON.
YES
• Turn starting switch ON. Is voltage between P01 (8) and NO disconnection in wiring Repair or
• Turn light switch ON. ground 20 – 30 V? harness between P01 (female) replace
(8) and M07 (male) (1)
YES
20-624 PC750, 800-6

M-15 Engine water temperature display is not normal

a) Gauge does not go up
Cause Remedy
1
Is service code [E934] or [E96A] NO
displayed at same time? Defective monitor panel Replace

(go to E Mode)
b) Gauges do not give display (no stage is displayed)
Cause Remedy
1
Is service code [E934] or [E96A] NO
(go to E Mode)
PC750, 800-6 20-625

M-16 Fuel level gauge display is not normal

a) Fuel level gauge always displays FULL
fl Check the level in the fuel tank before carrying out troubleshooting.
Cause Remedy
1
When P06 is disconnected, does NO
• Turn starting switch ON. gauge go down slowly to E range
(left side) and finally flash?
YES
system (go to M-20) Replace
2
• Turn starting switch Short circuit with ground in
Is resistance between C03 NO Repair or
OFF. (female) (2) and ground more wiring harness between C03
• Disconnect C03 and than 1 MΩ? (female) (2) and P06 (female) replace
P06. YES (1)
3
• Turn starting switch ON. Is less than 408 displayed for NO
• Set monitoring code to fuel level sensor input voltage Defective monitor panel Replace
[42]. of monitoring code [42]?
YES
b) Fuel level gauge does not give display (no stage is displayed)
fl Check the level in the fuel tank before carrying out troubleshooting.
Cause Remedy
1
• Disconnect P06. When P06 (female) (1) is connected NO
• Turn starting switch ON. to ground, does display go up
slowly to F range (right side)?
YES
system (go to M-20) Replace

OFF. Short circuit with ground in
Is resistance between C03 NO wiring harness between C03 Repair or
• Disconnect C03 and (female) (2) and ground less
P06. than 1 Ω? (female) (2) and P06 (female) replace
• Connect P06 (female)
YES (1)
(1) to ground.
3
• Turn starting switch ON. Is less than 408 displayed for NO
• Set monitoring code to fuel level sensor input voltage Defective monitor panel Replace
[42]. of monitoring code [42]?
YES
20-626 PC750, 800-6

PC750, 800-6 20-627

M-17 Swing lock switch is turned ON but swing lock monitor lamp
does not light up
fl Check that the swing lock is actually being actuated before carrying out troubleshooting.
Cause Remedy
1
Is voltage between P01 NO disconnection in wiring
• Turn starting switch ON. (female) (5) and ground as Repair or
shown in Table 1? harness between P01 (female) replace
(5) and X05 (male) (1)
YES
Table 1
Swing lock switch Voltage
ON Max. 1 V
OFF 20 – 30 V
20-628 PC750, 800-6

M-18 When swing brake release switch is set to RELEASE

(EMERGENCY), swing lock monitor lamp does not flash
fl Check that the swing brake is released before carrying out troubleshooting.
Cause Remedy
Is voltage between C17 (8) and NO disconnection in wiring Repair or
• Turn starting switch ON. ground as shown in Table 1? harness between C17 (female) replace
YES (8) and SW1 (4)
2
• Set monitoring code to Defective pump controller Replace
YES
Table 1
Swing brake release switch Voltage
ON Max. 1 V
OFF 20 – 30 V
PC750, 800-6 20-629

M-19 Service meter does not give normal display

a) Service meter does not advance when engine is running
Cause Remedy
1
• Run engine at mid- Is charge caution lamp NO
range speed. flashing?
YES
Go to Troubleshooting M-10 —
2
• Run engine at mid- Is more than 100 displayed for NO
range speed. alternator input voltage of Defective pump controller Replace
[43].
YES
b) When starting switch is OFF, service meter does not give display when time switch is pressed
Cause Remedy
1
When starting switch is ON, NO
• Turn starting switch ON. does monitor panel give Go to Troubleshooting M-5 —
normal display?
YES
20-630 PC750, 800-6

M-20 Defective fuel level sensor system

fl Remove the fuel level sensor when carrying out the troubleshooting.
Cause Remedy
1
When float is moved up and down, is NO
resistance between connector (1)
and flange as shown in table?
YES
2
NO
Does arm move smoothly? Defective sensor (Note 2) Replace
YES
3
Clean
Is there any large crack, chip, NO Defective contact of connector connector
or damage to float? or replace
YES
Interference with sensor Replace
inside tank (Note 2)
4
Check wiring harness visually. NO Replace
Defective sensor
Is it broken?
YES Disconnection in wiring
harness (Note 3) Replace
(defective clamp) sensor
(external force applied)
Table
Top (FULL) stopper position Approx. 12 Ω or below
Bottom (EMPTY) stopper position Approx. 85 – 110 Ω
Note 1: Difference between fuel level and gauge display

For gauge display position 9 (F), the amount of fuel is 60 – 100%; and for display position 1 (E)
it is below 10%. Furhtermore, if the chassis is at an angle, the displayed amount of fuel will be
different from the actual amount. Therefore, when checking, stop the machine at a horizontal
place and wait for at least 2 minutes before checking the gauge. (The display is given a time
delay so that the gauge can deal with sudden changes in the fuel level.)
Note 2: There is the possibility of defective installation or interference with the sensor inside the tank,
so be careful when installing.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropri-
ate action.
PC750, 800-6 20-631

M-21 Defective engine oil level sensor system

fl Remove the engine oil level sensor when carrying out the troubleshooting.
Cause Remedy
1
Check wiring harness visually. NO
Is it broken?
Replace
harness (Note 3) (defective
sensor
clamp) (external force applied)
2
Is any dirt stuck to moving part NO
of float?
YES
Defective movement of float
due to dirt Clean
3
Clean
or damage to float? (Note 2) or replace
YES
4
NO Defective sensor Replace
Is there resonance at mount?
YES Replace
Resonance of mount (Note 3) sensor
(Note 4)
Note 1: Variations in oil level

The oil level may change according to the angle of the machine, the engine speed, or the
temperature of the oil, so if there is any display, check the oil level again with the machine at
a horizontal place.
Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective,
so check the connector and wiring harness at the chassis end.
ate action.
Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs
again, check for any vibration of the mount, and if there is excessive vibration, take the
appropriate action.
20-632 PC750, 800-6

M-22 Defective coolant level sensor system

fl Remove the coolant level sensor when carrying out troubleshooting.
Cause Remedy
1
When float is moved up and down, NO
is resistance between connector
(1) and (2) as shown in Table?
YES
2
of float?
YES
Clean
due to dirt
3
Clean
YES Replace
(Note 4)
4
Defective sensor Replace
Is it broken?
Table (external force applied)
Float UP Max. 1 Ω
Float DOWN Min. 1 MΩ
Note 1: Variations in coolant level

The coolant level may change according to the angle of the machine, or the swaying of the
machine, so if there is any display, check the coolant level again with the machine at a
horizontal place.
ate action.
Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs
appropriate action.
PC750, 800-6 20-633

M-23 Defective hydraulic oil level sensor system

fl Remove the hydraulic oil level sensor when carrying out troubleshooting.
Cause Remedy
1
When float is moved up and down, NO
is resistance between connector
(1) and flange as shown in Table?
YES
2
of float?
YES
Clean
due to dirt
3
Clean
YES Replace
(Note 4)
4
Defective sensor Replace
Is it broken?
Table (external force applied)
Float UP Max. 1 Ω
Float DOWN Min. 1 MΩ
Note 1: Variations in hydraulic oil level

The hydraulic oil level may change according to the angle of the machine, or the swaying of
the machine, so if there is any display, check the hydraulic oil level again with the machine at
a horizontal place.
ate action.
Note 4: Defective installation is a possible cause, so be careful when in-stalling. If the problem occurs
appropriate action.
20-634 PC750, 800-6

M-24 Wiper is not actuated when wiper switch is operated or wiper is

actuated when wiper switch is not operated
a) Wiper is not actuated when switch is operated (including when service code [E112], [E113] are displayed)
fl Before carrying out troubleshooting, check that circuit breakers 2 or 9 have not shut off the
circuit. (If the breaker has shut off the circuit, there has probably been a surge of current caused
by a short circuit with the ground, so check the circuits related to circuit breakers 2 and 9.)
Cause Remedy
1
• Turn starting switch ON. When front window is closed, NO
• Set monitoring code to does bit (4) of monitoring code
[48]. [48] light up?
YES

2
OFF. Is resistance between W10 NO Defective rear limit switch or Repair or
• Disconnect W10. (female) (3) and (4) less than 1 Ω? front window is open replace
• Close front window.
YES
• Turn starting switch Is resistance between W10 (female) (3) NO harness between W10
OFF. and P02 (female) (13), and between W10 (female) (3) and P02 (female) Repair or
• Disconnect W10 and (female) (4) and ground less than 1 Ω? (13), between W10 (female) (4) replace
P02. YES and ground
4
• Turn starting switch ON. When wiper switch is turned to NO
• Set monitoring code to ON or INT, does bit (1) or (2) of
[48]. monitoring code [48] go out?
YES
5
• Turn starting switch Is resistance between pins of NO Defective wiper and washer
OFF. M18 (female) (1) (2) (4) as Replace
• Disconnect M18. shown in Table 3? switch
YES
• Turn starting switch Is resistance between each pin NO
OFF. of P02 (female), W04 (male) as disconnection in wiring Repair or
• Disconnect P02 and shown in Table 2? harness with defective replace
W04. YES resistance value
7
• Set monitoring code to ON or INT, does bit (3) or (4) of
[47]. monitoring code [47] light up?
YES
8
• Set service code to
being displayed? Short circuit with power
display mode.
source in wiring harness
YES
between P02 (female) (3) and Repair or
W08 (female) (18) or between replace
P02 (female) (11) and W08
9 (female) (17)
• Set monitoring code to OFF, does bit (2) or (3) of Defective monitor panel Replace
[4C]. monitoring code [4C] light up? Defective contact or
YES disconnection in wiring
harness between P02 (female) Repair or
(3) and W08 (female) (18) or replace
between P02 (female) (11) and
W08 (female) (17)
Go to next page
PC750, 800-6 20-635

From previous page Cause Remedy

10
Is voltage of each pin of W04 NO
as shown in Table 1?
YES
• Turn starting switch Is resistance between each pin of NO
OFF. P02 (female), W04 (male), W08 disconnection in wiring Repair or
• Disconnect P02, W04, (female) as shown in Table 2? harness with defective replace
and W08. YES resistance value
Defective relay box Replace
Table 1
(1) Timing chart (when wiper switch is ON)
Wiper switch ON
Item Symbol Set time
operation
OFF Length of pause until
next actuation Tia 0.13sec
P contact ON Tsp
r – t OFF Safety circuit during
Wiper motor
operation of wiper Tsa 10sec

[safety function (1)]
Tsa
W contact ON Tsa
y – t OFF Length of pause when
stowing wiper blade Tip 1.5sec
Normal Tia Tip
W04 rotation ON Tia Safety circuit during
e–t stowing of wiper
OFF Tsp 10sec
Reverse [safety function (2)]
rotation ON
q–t
fl Voltage when OFF: Max. 3 V; when ON: 20 – 30 V
(2) Timing chart (when wiper switch is at INT)
INT Item Symbol Set time

Wiper switch
operation OFF Length of pause until
next actuation Tia 4sec
P contact ON Tsp
r – t OFF
Safety circuit during
operation of wiper
Wiper motor
Tsa 10sec
[safety function (1)]
Tsa
W contact ON Tsa
y – t OFF Length of pause when
stowing wiper blade Tip 1.5sec
Normal Tia Tia Tip
W04 rotation ON Safety circuit during
e–t stowing of wiper Tsp 10sec
Reverse OFF [safety function (2)]
rotation
q – t ON
fl Voltage when OFF: Max. 3 V; when ON: 20 – 30 V
Table 2 Table 3
Resistance Wiper switch M18 (female) P02 (female) Resistance value
W04 (male), W08 (female), P02 (female)
value Between (1) and (2) Between (1) and (4) Min. 1 MΩ
Between W04 (1) and W08 (6) INT Between (1) and (4) Between (1) and (12) Max. 1 Ω
Between W04 (3) and W08 (7) Between (2) and (4) Between (4) and (12) Min. 1 MΩ
Between W04 (4) and P02 (15) Max. 1 Ω Between (1) and (2) Between (1) and (4)
Between W04 (5) and ground OFF Between (1) and (4) Between (1) and (12) Min. 1 MΩ
Between W04 (6) and P02 (6) Between (2) and (4) Between (4) and (12)
Between W04 (1)(3)(4)(6) and ground Min. 1 MΩ Between (1) and (2) Between (1) and (4) Max. 1 Ω
Between W08 (17) and P02 (11) ON Between (1) and (4) Between (1) and (12)
Max. 1 Ω Min. 1 MΩ
20-636 PC750, 800-6

b) Wiper switch is not being operated, but wiper is actuated
Cause Remedy
1
YES
2
• Turn starting switch ON. Is bit (3) or (4) of monitoring NO
[47].
code [47] lighted up?
YES
3
• Turn starting switch ON. Is bit (2) or (3) of monitoring NO
[4C].
code [4C] lighted up? Short circuit with ground in
YES wiring harness between P02
(female) (3) and W08 (female) Repair or
(18) or between P02 (female) replace
(11) and W08 (female) (17)
4 Short circuit with power source

Is voltage between W08 (female) NO in wiring harness between W08 Repair or
• Disconnect W08. (female) (7) and W04 (male) (3)
(1) and (6), and between (1) and replace
(7) less than 1 V? or between W08 (female) (6)
YES and W04 (male) (1)
Defective relay box Replace
5
Has bit (1) or (4) of monitoring NO
• Set monitoring code to Go to Troubleshooting No. 7 —
[48]. code [48] gone out?
YES
6
• Turn starting switch Is resistance between each pin NO Defective wiper and washer
OFF. of M18 (female) (1)(2)(4) as Replace
• Disconnect M18. shown in Table 1? switch
YES
• Turn starting switch Is resistance between each pin NO
OFF. disconnection in wiring Repair or
of P02 (female), W04 (male) as harness with defective replace
• Disconnect P02, W04, shown in Table 2?
and W08. resistance value
YES
PC750, 800-6 20-637

Table 1 Table 2
Wiper switch M18 (female) P02 (female) Resistance value
W04 (male), W08 (female), P02 (female) Resistance
value Between (1) and (2) Between (1) and (4) Min. 1 MΩ
Between W04 (1) and W08 (6) INT Between (1) and (4) Between (1) and (12) Max. 1 Ω
Between W04 (3) and W08 (7) Between (2) and (4) Between (4) and (12) Min. 1 MΩ
Between W04 (4) and P02 (15) Max. 1 Ω Between (1) and (2) Between (1) and (4)
Between W04 (5) and ground OFF Between (1) and (4) Between (1) and (12) Min. 1 MΩ
Between W04 (1)(3)(4)(6) and ground Min. 1 MΩ Between (1) and (2) Between (1) and (4) Max. 1 Ω
Between W08 (17) and P02(11) ON Between (1) and (4) Between (1) and (12)
Max. 1 Ω Min. 1 MΩ
20-638 PC750, 800-6

PC750, 800-6 20-639

M-25 Window washer is not actuated when wiper switch is operated

or window washer is actuated when switch is not operated
a) Window washer is not actuated when switch is operated (when service code [E114] is displayed)
fl Before carrying out troubleshooting, check that circuit breaker 1 has not shut off the circuit,
and that fuse 7 is not blown. (If the breaker has shut off the circuit or the fuse is blown, there
has probably been a surge of current caused by a short circuit with the ground, so check the
circuits related to circuit breaker 1 and fuse 7.)
Cause Remedy
1
• Disconnect P02 and Is voltage between P02 Short circuit with power
NO source in wiring harness Repair or
M28. (female) (2) (10), M28 (female)
• Turn starting switch ON. (1) – ground less than 1 V? between P02 (female) (2) (10) replace
YES and M28 (female) (1)
2
• Turn starting switch Is resistance between M28 NO Defective washer motor
OFF. Replace
(male) (1) and (2) 5 – 20 Ω?
• Disconnect M28.
YES
20-640 PC750, 800-6

b) Window washer is not actuated when wiper switch is operated (when service code [E114] is displayed)
fl Before carrying out troubleshooting, check that circuit breaker 1 has not shut off the circuit,
and that fuse 7 is not blown. (If the breaker has shut off the circuit or the fuse is blown, there
has probably been a surge of current caused by a short circuit with the ground, so check the
circuits related to circuit breaker 1 and fuse 7.)
• Turn starting switch ON. Cause Remedy

• Wiper washer switch:
1
WASH I, WASH II: Is voltage between P02 (2) (10) NO
Max. 1 V – (9) as shown on left?
Washer switch OFF:
20 – 30 V YES
2
• Measurement Is voltage between P02 (5) and NO
conditions same as
(9) as shown on left?
above.
YES
OFF. 3
• Wiper washer switch:
WASH I, WASH II:
Is resistance between M18 NO Defective wiper and washer
(female) (1) and (3) as shown Replace
Max. 1 Ω on left? switch
Washer switch OFF:
Min. 1 MΩ YES
• Disconnect M18.
• Turn starting switch Is resistance between M18 NO
OFF. (male) (1) and chassis less harness between M18 (male) replace
• Disconnect M18. than 1 Ω? (1) – X01 (21) – chassis
YES Disconnection or short circuit
with power source in wiring Repair or
(5) – X01 (10) – M18 (male) (3)
Is voltage between M28 (2) NO disconnection in wiring Repair or
• Turn starting switch ON. harness between fuse 7 – H12 replace
and chassis 20 – 30 V?
(14) – M28 (female) (2)
YES
Disconnection or short circuit
with ground in wiring harness Repair or
between M28 (female) (1) – replace
H12 (11) – P02 (female) (2) (10)
c) Wiper switch is not being operated, but window washer is actuated
Cause Remedy
• Turn starting switch Is resistance between P02
OFF. (female) (5), M18 (male) (3) – NO wiring harness between P02 Repair or
• Disconnect P02, M18, ground more than 1 MΩ? (female) (5) and M18 (male) replace
and W10. YES (3)
PC750, 800-6 20-641

20-642 PC750, 800-6

M-26 Electric grease gun does not work (machines equipped with
electric grease gun)
Cause Remedy
1
Is voltage between G01 (1) and NO
ground 20 – 28V?
YES
2
• Turn starting switch Is resistance between G01 NO Repair or
OFF. (male) (2) and ground less disconnection in wiring
• Disconnect G01. than 1 Ω? harness between G01 (male) replace
YES (2) and ground
3
Is voltage between G02 Defective contact or
• Turn starting switch ON. NO disconnection in wiring Repair or
• Disconnect G02.
(female) (1) and ground 20 –
28V? harness between battery relay replace
YES terminal M and G02 (male) (1)
4
• Turn starting switch Is resistance between each pin NO Defective grease gun remote
OFF. of G02 (female) as shown in switch Replace
• Disconnect G02. Table 1?
harness between G02 (male) replace
(2) and G01 (male) (1)
Table 1
Grease gun remote switch G02 (female) Resistance value
OFF Between (1) and (2) Min. 1 MΩ
ON Between (1) and (2) Max. 1 Ω
PC750, 800-6 20-643

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ................. 30- 3 RECOIL SPRING ASSEMBLY

PRECAUTIONS WHEN CARRYING OUT Removal, Installation ......................... 30- 73
OPERATION .......................................... 30- 6 RECOIL SPRING ASSEMBLY
SPECIAL TOOL LIST .................................. 30- 8 Disassembly, Assembly .................... 30- 75
SKETCHES OF SPECIAL TOOLS ............... 30-16 CARRIER ROLLER ASSEMBLY
AFTERCOOLER CORE Removal, Installation ........................... 30- 77
Removal Installation ............................ 30-17 CARRIER ROLLER ASSEMBLY
FAN GUARD, RADIATOR, HYDRAULIC Disassembly, Assembly ...................... 30- 78
COOLER ASSEMBLY TRACK ROLLER ASSEMBLY
Removal, Installation ........................... 30-18 Removal, Installation ........................... 30- 80
FUEL COOLER AND AIR CONDITIONER TRACK ROLLER ASSEMBLY
CONDENSER ASSEMBLY Disassembly, Assembly ...................... 30- 81
Removal, Installation ........................... 30-21 HYDRAULIC TANK ASSEMBLY
FUEL TANK ASSEMBLY Removal, Installation ........................... 30- 84
Removal, Installation ........................... 30-22 MAIN PUMP (NO. 1 PUMP) ASSEMBLY
ENGINE, PTO, HYDRAULIC PUMP Removal, Installation ........................... 30- 87
ASSEMBLY MAIN PUMP (NO. 2 PUMP) ASSEMBLY
PTO ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL
PTO ASSEMBLY CONTROL, PTO LUBRICATION PUMP
Disassembly, Assembly ...................... 30-31 ASSEMBLY
FINAL DRIVE ASSEMBLY Removal, Installation ........................... 30- 92
Disassembly, Assembly ...................... 30-35 MAIN RELIEF VALVE ASSEMBLY
REVOLVING FRAME ASSEMBLY Disassembly, Assembly ...................... 30- 93
Removal, Installation ........................... 30-48 CONTROL VALVE ASSEMBLY
SWING MACHINERY ASSEMBLY Removal, Installation ........................... 30- 94
Removal, Installation ........................... 30-50 Disassembly, Assembly ...................... 30- 98
SWING MACHINERY ASSEMBLY SOLENOID VALVE ASSEMBLY
Disassembly, Assembly ...................... 30-51 Removal, Installation ........................... 30-102
SWING CIRCLE ASSEMBLY BOOM DAMPING VALVE ASSEMBLY
Removal, Installation ........................... 30-60 Removal, Installation ........................... 30-104
TRACK SHOE ASSEMBLY SWING MOTOR ASSEMBLY
ONE LINK IN FIELD CENTER SWIVEL JOINT ASSEMBLY
IDLER ASSEMBLY CENTER SWIVEL JOINT ASSEMBLY
Removal, Installation ........................... 30-67 Disassembly, Assembly ...................... 30-107
IDLER ASSEMBLY TRAVEL MOTOR ASSEMBLY
IDLER ADJUSTMENT CYLINDER WORK EQUIPMENT PPC VALVE
ASSEMBLY ASSEMBLY
Disassembly, Assembly ...................... 30-72 Disassembly, Assembly ...................... 30-109
PC750, 800-6 30-1

1
TRAVEL PPC VALVE ASSEMBLY BUCKET ASSEMBLY
BUCKET CYLINDER ASSEMBLY ARM ASSEMBLY
ARM CYLINDER ASSEMBLY BOOM ASSEMBLY
BOOM CYLINDER ASSEMBLY WORK EQUIPMENT ASSEMBLY
BOTTOM DUMP CYLINDER ASSEMBLY OPERATOR’S CAB ASSEMBLY
HYDRAULIC CYLINDER ASSEMBLY COUNTERWEIGHT ASSEMBLY
30-2 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
1 When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
2 Any special techniques applying only to the installation procedure are marked 1, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF ASSEMBLY ............ Title of operation
 ...................................................................... Precautions related to safety when carrying out
the operation
1. X X X X (1) ..................................................... Step in operation
fl .................................................................. Technique or important point to remember
when removing XXXX (1).
2. (2): ............................................... 1 Indicates that a technique is listed for use
during installation
3. assembly (3)
6 ............................................................ Quantity of oil or water drained
INSTALLATION OF ASSEMBLY ....Title of operation

• Carry out installation in the reverse order to removal.
1 ............................................................. Technique used during installation
fl .................................................................. Technique or important point to remember when
installing (2).
• Adding water, oil ................................. Step in operation
fl ............................................................ Point to remember when adding water or oil
-......................................................... Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools

1 For details of the description, part number, and quantity of any tools (A1, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
PC750, 800-6 30-3

1
4. Standard tightening torques of bolts and nuts

Use these torques for metric bolts and nuts. (Always use torque wrench).
Thread diameter Width

of bolt across flats
mm mm Nm kgm
6 10 13.2 ± 1.4 1.35 ± 0.15
8 13 31 ± 3 3.2 ± 0.3
10 17 66 ± 7 6.7 ± 0.7
12 19 113 ± 10 11.5 ± 1
14 22 177 ± 19 18 ± 2
16 24 279 ± 30 28.5 ± 3
18 27 382 ± 39 39 ± 4
20 30 549 ± 59 56 ± 6
22 32 745 ± 83 76 ± 8.5
24 36 927 ± 103 94.5 ± 10.5
27 41 1320 ± 140 135 ± 15
30 46 1720 ± 190 175 ± 20
33 50 2210 ± 240 225 ± 25
36 55 2750 ± 290 280 ± 30
39 60 3290 ± 340 335 ± 35
Thread diameter Width

of bolt across flats
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
5. Tightening torque of hose nuts

Use these torques for hose nuts.
Nominal No.
mm mm Nm kgm
02 14 19 24.5 ± 4.9 2.5 ± 0.5
03 18 24 49 ± 19.6 5±2
04 22 27 78.5 ± 19.6 8±2
05 24 32 137.3 ± 29.4 14 ± 3
06 30 36 176.5 ± 29.4 18 ± 3
10 33 41 196.1 ± 49 20 ± 5
12 36 46 245.2 ± 49 25 ± 5
14 42 55 294.2 ± 49 30 ± 5
6. Tightening torque of split flange bolts

Use these torques for split flange bolts.
mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
30-4 PC750, 800-6

1
7. Tightening torque of O-ring boss connector

Use these torques for O-ring boss connector

Nominal No.
mm mm Nm kgm
02 14 34.3 ± 4.9 3.5 ± 0.5
03, 04 20 Varies depending on 93.1 ± 9.8 9.5 ± 1
05, 06 24 type of connector. 142.1 ± 19.6 14.5 ± 2
10, 12 33 421.4 ± 58.8 43 ± 6
14 42 877.1 ± 132.3 89.5 ± 13.5
8. Tightening torque of O-ring boss connector

Use these torques for O-ring boss connector

Nominal No.
mm mm Nm kgm
08 8 14 7.35 ± 1.47 0.75 ± 0.15
10 10 17 11.27 ± 1.47 1.15 ± 0.15
12 12 19 17.64 ± 1.96 1.8 ± 0.2
14 14 22 22.54 ± 1.96 2.3 ± 0.2
16 16 24 29.4 ± 4.9 3 ± 0.5
18 18 27 39.2 ± 4.9 4 ± 0.5
20 20 30 49 ± 4.9 5 ± 0.5
24 24 32 68.6 ± 9.8 7± 1
30 30 32 107.8 ± 14.7 11 ± 1.5
33 33 — 127.4 ± 19.6 13 ± 2
36 36 36 151.9 ± 24.5 15.5 ± 2.5
42 42 — 210.7 ± 29.4 21.5 ± 3
52 52 — 323.4 ± 44.1 33 ± 4.5
PC750, 800-6 30-5

1
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
fl Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
number
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18 Taper 1/8
øD
ød
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
L
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
DEW00401
30-6 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
fl When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times,
stopping the cylinder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
fl When using the machine for the first time after repair or long storage, follow the same
procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
fl For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
PC750, 800-6 30-7

1
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

fl Tools with part number 79T- - cannot be supplied (they are items to be locally manufac-
tured).
fl Necessity: ■: Cannot be substituted, should always be installed (used).
●: Extremely useful if available, can be substituted with commercially available part.
fl New/remodel: N: Tools with new part numbers, newly developed for this model.
fl R: Tools with upgraded part numbers, remodeled from items already available for
other models.
fl Blank: Tools already available for other models, used without any modification.
fl Tools marked in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
New/
Component Symbol Part No. Part Name Q’ty Sketch Nature of work, remarks
remodel
790-101-5401 Push tool kit 1
Disassembly, assembly
790-101-5541 • Plate 1
1 Press fitting of oil seal
790-101-5421 • Grip 1
Swing machinery F 01010-81240 • Bolt 1

assembly 790-201-2780 Spacer 1 Press fitting of main bearing
2
790-201-2880 Spacer 1 Press fitting of main bearing
3 796T-626-1130 Push tool 1 N fi Press fitting of sub bearing
1 796-627-1050 Installer 1 Installation of floating seal
2 796-627-1030 Push tool 1 R Press fitting of bearing outer race
790-101-2300 Push-puller 1
• 790-101-2310 • Block 1
• 790-101-2350 • Leg 2
• 790-101-2360 • Plate 2 Press fitting of bearing
3 • 02215-11622 • Nut 2 inner race
791-181-1010 Adapter 2
796T-627-1340 Push tool 1 N fi
790-101-2102 Puller (294 kN {30 ton}) 1 Long stroke
790-101-1102 Pump 1
Final drive assembly J 4 790-627-1200 Wrench assembly 1 N Removal, installation of round nut
796-627-1070 Spacer 1 N
Removal of No. 1 carrier
5 01017-52450 Bolt 1
pin holder
01580-12419 Nut 1
790-201-2830 Spacer 1
6 Removal of No. 1 carrier pin
790-101-5151 Plate 1
790-101-5401 Push tool kit (C) 1
Press fitting of bearing
• 790-101-5441 • Plate 1
7 outer race
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-5001 Push tool kit (A) 1 Press fitting of needle bearing
• 790-101-5151 • Plate 1 No. 2 carrier
8
• 790-101-5061 • Plate 1 No. 3 carrier
• 790-101-5021 • Grip 1
30-8 PC750, 800-6

1
New/
remodel
assembly installation
Disassembly, Disassembly, Removal,
Removal, installation of
Travel motor assembly K 796-660-1560 Guide bolt 2 N
travel motor assembly
1 790-201-2680 Plate 1 Press fitting of idler bushing

Idler assembly
2 796-675-1510 Installer 1 Installation of idler floating seal
3 790-1101-5401 Push tool kit (C) 1 Carrier roller bearing
assembly
4 796T-630-1130 Push tool 1 Installation of floating seal
Carrier roller assembly
5 796T-630-1140 Adapter 1 N fi Press fitting of carrier roller bearing inner race
791-401-1700 Lifting tool 1
791-401-1761 Adapter 1 Removal, installation of
7
791-401-1540 Shackle 2 track roller assembly
791-401-1770 T-bolt 2
Track roller assembly
9 790-201-2670 Plate 1 Press fitting of track roller bushing
791-601-1000 Oil pump 1
or Filling with oil,
10
791-646-8002 Oil lubricator 1 checking sealing
790-701-3000 Seal checker 1

791-680-9501 Remover, installer 1
installation
791-101-4300 Cylinder (1,471 kN {150 ton}) 1

Removal,
1
Track shoe assembly 791-101-4200 Puller (294 kN {30 ton}) master pin
791-101-1102 Pump
2 790-331-1100 Wrench Tightening shoe bolt angle
791-685-8501 Compressor 1
M 791-635-3160 Extension 1
796-630-1110 Plate 1
01010-51640 Bolt 2 Disassembly, assembly of
Recoil spring assembly 3
791-630-1120 Spacer 1 recoil spring
790-101-1600 Cylinder (686 kN {70 ton}) 1

790-010-1102 Pump 1
796-630-1110 Plate 1
791-680-9580 Adapter 1
791-680-9590 Guide 1
1
01010-52760 Bolt 2
Track link remover N
01010-51440 Bolt 2
790-101-1102 Pump 1
2
790-101-4300 Cylinder 1 1,471 kN {150 ton}
PC750, 800-6 30-9

1
New/
remodel
791-685-9510 Frame 1
791-685-9520 Frame 1
Assembly
791-685-9530 Rod 1
791-685-9550 Nut 1
791-685-9560 Bolt 4
3
791-680-9570 Adapter 1
01010-51030 Bolt 1
04530-12030 Eyebolt 1
790-101-1102 Pump 1
790-101-4300 Cylinder 1 1,471 kN {150 ton}
791-685-9540 Rod 1
4
791-685-9550 Nut 3
791-685-9510 Frame 1
Track link remover N 791-685-9520 Frame 1
791-685-9530 Rod 1
791-685-9550 Nut 1
791-685-9560 Bolt 4
791-126-0150 Adapter 1
791-680-5520 Guide 1
5
791-126-0140 Pusher 1
791-680-9570 Adapter 1
01010-51030 Bolt 1
04530-12030 Eyebolt 1
791-685-9620 Extension 1
791-101-1102 Pump 1
790-101-4300 Cylinder 1 1,471 kN {150 ton}
790-101-1102 Pump 1
6
790-101-4200 Pulley 1 294 kN {30 ton}
Disassembly
791-680-5542 Adapter 1 Press fitting of regular pin

7
Track link installer 791-632-1110 Adapter 1 Press fitting of bushing
8 791-680-5580 Guide 1
30-10 PC750, 800-6

1
New/
remodel
791-685-9510 Frame 1
791-685-9520 Frame 1
791-685-9530 Rod 1
Assembly
791-685-9540 Rod 1
791-685-9550 Nut 3
791-685-9560 Bolt 4
9 791-126-0150 Adapter 1
01010-51030 Bolt 1
791-685-9620 Extension 1
791-680-5542 Adapter 1
791-680-5560 Guide 1
790-101-1102 Pump 1
790-101-4300 Cylinder 1 1,471 kN {150 ton}
791-685-9510 Frame 1
791-685-9520 Frame 1
791-685-9530 Rod 1
Track link installer N 791-685-9540 Rod 1
791-685-9550 Nut 3
791-685-9560 Bolt 4
791-126-0150 Adapter 1
10
01010-51030 Bolt 1
791-685-9620 Extension 1
791-680-5560 Guide 1
791-632-1110 Adapter 1
791-680-9630 Adapter 1
790-101-1102 Pump 1
790-101-4300 Cylinder 1 1,471 kN {150 ton}
11 790-680-1520 Guide 1
791-685-9510 Frame 1
791-685-9520 Frame 1
12 791-685-9530 Rod 1
791-685-9540 Rod 1
791-685-9550 Nut 3
PC750, 800-6 30-11

1
New/
remodel
791-685-9560 Bolt 4
791-126-0150 Adapter 1
791-680-5560 Guide 1
791-680-9570 Adapter 1
12
01010-51030 Bolt 1
Track link installer
791-680-1520 Guide 1
790-101-1102 Pump 1
N
790-101-4300 Cylinder 1 1,471 kN {150 ton}
790-101-1102 Pump 1
13
790-101-4200 Pulley 1 294 kN {30 ton}
791-680-9501 Remover, installer 1 Kit
Track link remover, 790-101-1102 Pump 1

14
installer 790-101-4200 Pulley 1 294 kN {30 ton}
790-101-4300 Cylinder 1 1,471 kN {150 ton}
installation
Removal,
1 796-770-1301 Oil stopper 1 hydraulic pump
2 209-60-71130 Rod assembly 1 Disassembly,

assembly
Hydraulic pump 3 790-101-5001 Push tool kit 1
assembly S
Press fitting of oil seal
4 • 790-101-5151 • Plate 1
(hydraulic pump shaft)
5 • 790-101-5021 • Grip 1
6 01010-50816 • Bolt 1
790-101-2510 Push-puller 1
• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
Center swivel joint Disassembly of center
assembly T • 790-101-2540 • Washer 2 swivel joint
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 2
• 790-101-2560 • Nut 2
• 790-101-2660 • Adapter 2
30-12 PC750, 800-6

1
New/
remodel
1 790-502-1003 Cylinder repair stand 2 Disassembly, assembly of hydraulic cylinder
2 790-720-1000 Expander 1 N fi Installation of piston ring
796-720-1690 Ring 1 Boom, arm cylinder
Disassembly
796-720-1720 Ring 1 Bucket cylinder (for SE)
07281-02169 Clamp 1 Boom, arm cylinder
3
796-720-1690 Ring 1 Bucket cylinder
07281-01919 Clamp 1
07281-02429 Clamp 1 Bucket cylinder (for SE)
790-201-1702 Push tool kit 1 Press fitting of coil bushing
• 790-201-1881 • Push tool 1 Boom, arm cylinder
• 790-201-1871 • Push tool 1 Arm cylinder (for SE), bucket cylinder
Hydraulic cylinder • 791-863-1110 • Push tool 1 Bucket cylinder (for SE)

U 4
assembly • 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
Assembly
• 790-101-5021 • Grip 1
All cylinders
• 01010-50816 • Bolt 1
790-201-1500 Push tool kit 1 Press fitting of dust seal
• 790-201-1690 • Plate 1 Boom, arm cylinder
• 790-201-1680 • Plate 1 Bucket cylinder
5
• 792-715-1400 • Push tool 1
• 790-101-5421 • Grip 1 Bucket cylinder (for SE)
• 01010-51240 • Bolt 1
Disassembly,
• 790-101-5201 • Grip 1 Press fitting of dust seal

assembly
6
• 01010-51240 • Bolt 1 All cylinders
790-445-4100 Remover 1 Removal of boom foot pin,
boom
1 790-101-4200 Puller (294 kN {30 ton}) 1 Short stroke
cylinder
Removal, installation
790-101-1102 Pump 1 bottom pin
791-650-1610 Bracket 1
Work equipment
assembly V 790-445-4130 Screw 1
Removal of arm cylinder
791-112-1180 Nut 1 rod head and bottom pin
2
01643-32780 Washer 1
790-101-2102 Puller (294 kN {30 ton}) 1 Long stroke
790-101-1102 Pump 1
PC750, 800-6 30-13

1
New/
remodel
790-445-4120 Sleeve 1 Removal of boom top pin
Removal, installation
791-520-4140 Screw 1 and boom cylinder head pin
796-775-1110 Adapter 1 Boom top pin only

Work equipment V 3 791-112-1180 Nut 1
assembly
01643-32780 Washer 1
790-101-2102 Puller (294 kN {30 ton}) 1
790-101-1102 Sleeve 1
799-703-1200 Service tool kit 1
installation
Removal,
799-703-1100 Vacuum pump (100 V) 1
Charging with
Air conditioner system X 799-703-1110 Vacuum pump (220 V) 1 freon gas (R134a)
799-703-1120 Vacuum pump (240 V) 1
799-703-1400 Gas leak detector 1
30-14 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools
manufactured according to these sketches.
F3 Push tool
J3 Push tool
PC750, 800-6 30-15

1
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
L-5 Adapter
30-16 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY AFTERCOOLER CORE
REMOVAL OF AFTERCOOLER
CORE
1. Lift off radiator grill (1).
2. Lift off radiator top cover (2).
3. Loosen clamps (3) of rubber hose.
4. Sling aftercooler core (4), remove mounting

bolts, and pull out from rubber hose while lift-
ing off.
INSTALLATION OF
AFTERCOOLER CORE
• Carry out installation in the reverse order to
removal.
PC750, 800-6 30-17

1
DISASSEMBLY AND ASSEMBLY FAN GUARD, RADIATOR, HYDRAULIC OIL COOLER
REMOVAL OF FAN GUARD,

RADIATOR AND HYDRAULIC
OIL COOLER ASSEMBLY
 Disconnect the (–) terminal of the battery in ad-
vance.
 Open the engine hood, and press the valve of
the compressor hose for the air conditioner
slowly to release refrigerant (R134a) gradually.”
 Lower the work equipment completely to the
ground and stop the engine. Loosen the oil filler
cap of the hydraulic tank slowly to release the
internal pressure.
1. Drain coolant, hydraulic oil and fuel. Recall the
air conditioner gas.
2. Lift the engine hood (1) on the front side and
remove it.
3. Remove the radiator grille (2) and the cover (3).
4. Loosen 2 bolts of the radiator grille (2) and open
the grille.
fl Remove the air conditioner condenser, the
fuel cooler and the after cooler referring to
the paragraph of Removal of Air Conditioner
Condenser, Fuel Cooler and After Cooler.
5. Remove the brackets (5) of the air conditioner

condenser and the fuel cooler.
6. Disconnect the radiator cooler tube (6) and the

radiator cooler hose (7).
7. Remove the fuel cooler hose clamp (8).
30-18 PC750, 800-6

1
8. Remove 3 pieces of the hose clamp (9) of the air

conditioner condenser.
9. Remove 2 pieces of the plate (10).
10. Disconnect the air intake hose (11) and the air
intake tube (12).
11. Disconnect the hoses (13), (14) and (15).
12. Reduce the tension of the tension pulley by us-
ing a lever block, for example, and remove the
fan belt.
13. Loosen the bolt of the frame (16) and remove it.
14. Lift the fan guard, radiator and hydraulic oil

cooler assembly temporarily and remove the
mounting bolts (17).
15. Remove the fan guard, radiator and hydraulic

oil cooler assembly (18).
4 Fan guard, radiator and hydraulic oil cooler

assembly: 950 kg
PC750, 800-6 30-19

1
16. Lower the fan pulley and set the block 1 be-
tween the fan guard, radiator and hydraulic oil
cooler assembly and the ground.
17. Lift the hydraulic oil cooler assembly (19) tem-

porarily, remove 8 pieces of the mounting bolt
(20) and then remove the hydraulic oil cooler
assembly.
4 Hydraulic oil cooler assembly: 200 kg
18. Lift the radiator (21) temporarily and remove 8

pieces of the mounting bolt (22).
19. Remove the isolator (23) and then remove the
radiator assembly.
4 Radiator assembly: 260 kg
INSTALLATION OF FAN
GUARD, RADIATOR AND
HYDRAULIC OIL COOLER
ASSEMBLY
• To install this assembly, reverse the removing
procedures.
• Water Filling
fl Fill water up to the specified level through
the water filler port, start the engine to cir-
culate coolant and check the water level
again.
• Filling (Hydraulic Tank) with Oil
fl Fill oil up to the specified level through the
oil filler port, start the engine to circulate oil
through the pipe and check the oil level
again.
• Filling of Air Conditioner Gas
fl Use the tool X and fill the air conditioner
circuit with refrigerant (R134a).
• Alignment of Engine Pulley and Fan Pulley
fl Assemble them so that the engine pulley
aligns with the fan pulley within 3 mm.
• Filling (Fuel Tank) with Diesel Fuel
fl Fill the fuel tank with diesel fuel through the
oil filler port and bleed air by the specified
method (See the Operation and Maintenance
Manual).
30-20 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY FUEL COOLER, AIR CONDITIONER CONDENSER
REMOVAL OF FUEL COOLER

AND AIR CONDITIONER
CONDENSER ASSEMBLY
ground and stop the engine. Loosen the cap of
the hydraulic tank slowly to release the internal
pressure of the hydraulic tank.
 Connect the tool X to the valve of the air com-
pressor hose and recall new Freon gas (R134a).
1. Shut the valve (1) of the fuel tank.
2. Open the radiator grille (2).
3. Remove the fuel cooler guard (3).

4. Disconnect the fuel cooler hoses (4) and (5).
5. Loosen 4 pieces of the fuel cooler mounting
bolt (6) and remove the fuel cooler (7).
6. Disconnect the air conditioner condenser hoses

(8) and (9).
7. Loosen 4 pieces of the air conditioner condenser
mounting bolt (10) and remove the air condi-
tioner condenser (11).
INSTALLATION OF FUEL
COOLER AND AIR
CONDITIONER CONDENSER
ASSEMBLY
procedures.
fl Fill new Freon gas (R134a).
PC750, 800-6 30-21

1
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
 Disconnect the (–) terminal of the battery in ad-
vance.
1. Open the drain valve and drain fuel.
6 Fuel tank:
880¬ (when the tank is fully filled)
2. Remove the handrail (1).
3. Remove the fuel gauge cover (2) and the fuel

gauge wiring cover (3), and disconnect the wir-
ing connector.
4. Disconnect the fuel return hoses (4) and (5) and

remove the hose clamps.
5. Disconnect the fuel supply hose (5) and the drain

hose (6).
30-22 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY FUEL TANK
6. Remove the control valve cover bracket (7).
7. Loosen the mounting bolt, lift the fuel tank as-

sembly and remove it.
4 Fuel tank assembly: 498 kg
INSTALLATION OF FUEL TANK

ASSEMBLY
procedures.
3 Fuel tank mounting bolt:
549 ± 58 Nm {56 ± 6kgm}
PC750, 800-6 30-23

1
DISASSEMBLY AND ASSEMBLY ENGINE, PTO, HYDRAULIC PUMP
REMOVAL OF ENGINE, PTO

AND HYDRAULIC PUMP
ASSEMBLY
the hydraulic tank slowly to release internal pres-
sure of the hydraulic tank.
 Drain engine oil.
 Disconnect the (–) terminal of the battery.
fl Put counter marks on each hose and tube, and
attach blind plugs to the disconnected hoses
and tubes.
1. Remove the strainer from the fuel tank and use
the oil stopper tool S to stop oil flow.
• When the tool S is not used, remove the
drain plug and drain oil.
6 Hydraulic tank: 500 ¬
2. Drain coolant.
3. Remove the engine oil filter cover (1) and re-
move the oil filter assembly (2) together with
the bracket (3) from the engine hood. Place them
on the control valve side.
4. Remove the radiator cover (4).

5. Remove the engine hood (5).
6. Remove the main pump cover (6).
7. Remove the partition cover (7) between the en-

gine and the main pump.
30-24 PC750, 800-6

1
Engine Left Side

8. Remove the air compressor cover (8) and loosen
the belt adjustment bolt to remove the belt.
9. Loosen 4 pieces of the compressor mounting
bolt (9), remove the compressor (10) and place
it on the control valve side.
10. Disconnect the aftercooler hose.
11. Remove the fuel cooler hose (11), the fuel hose
(12), the hose clamp (13), the engine breather
hose (14) and the clamp of the muffler drain
hose (15).
12. Remove the wiring connector (16) and the wir-

ing clamp (17).
13. Disconnect the engine oil filter hose (18).
14. Disconnect the air cleaner dust indicator hose

(19) and remove the wiring connector (20).
PC750, 800-6 30-25

1
Engine Right Side

15. Disconnect the aftercooler hose (21).
16. Disconnect the aeration hose (22) and the cool-
ant hose (23).
17. Disconnect the car heater hose (24) and the hose
clamp (25).
18. Disconnect the coolant hose (26).
20. Reduce the tension of the tension pulley (27)

and remove the fan belt (28).
21. Disconnect the starter wiring (29) and the ground

cable (30).
30-26 PC750, 800-6

1
22. Remove the TVC solenoid connector (31) and

the clamp, and disconnect the harness from the
pump.
23. Disconnect the jet sensor hoses (32) and (33) of
No. 1 pump.
24. Disconnect the CO cancel hose (34) and the pi-
lot pressure reducing hose (35).
25. Disconnect the servo valve hose (36) and the

safety valve hose (37).
26. Disconnect the control pump outlet hose (38).

27. Disconnect the outlet hoses (39) and (40) of No.
1 and No. 2 pumps and the drain hoses (41) and
(42).
28. Disconnect the suction tubes (43) and (44) and

the suction hose (45).
PC750, 800-6 30-27

1
29. Lift the engine, PTO and pump assembly tem-

porarily and remove the front mounting bolt (46),
the rear mounting bolt (47), the left and right
mounting bolts.
30. Lift the engine, PTO and pump assembly and

remove it.
fl Lift the assembly a little to prevent the fan
pulley from interfering, take out the front
mount, slide it backward and lift the assem-
bly.
4 Engine, PTO and pump assembly:

26,000 kg
INSTALLATION OF ENGINE,
PTO AND HYDRAULIC PUMP
ASSEMBLY
•To install this assembly, reverse the removing
procedures.
3 Mounting bolt:
926.1 ± 102.9 Nm {94.5 ± 10.5 kgm}
• Oil Filling
fl Fill oil up to the specified level, start the
engine to circulate oil throughout the pipe
and check the oil level.
• Water Filling
fl Fill water up to the specified level, start the
engine to circulate coolant throughout the
pipe and check the water level.
• Air Bleeding
Bleed air from the main pump referring to the
paragraph of “Bleeding Air from Main Pump” in
Testing and Adjusting.
30-28 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY PTO
REMOVAL OF PTO ASSEMBLY

1. Remove the engine, PTO and hydraulic pump
assembly referring to the paragraph of “Removal
of Engine, PTO and Hydraulic Pump Assembly”.
2. Lift No. 1 pump assembly (1) and remove it.
4 No. 1 pump assembly: 165 kg
3. Lift No. 2 pump assembly (2) and remove it.
4 No. pump assembly: 150 kg
4. Lift the control, PTO and lubrication pump as-

sembly (3) and remove it.
fl Take out the suction hose as well at the
same time.
5. Disconnect the lubrication hoses (7) and (11),

the lubrication tubes (4), (5), (6), (8), (9) and (10),
and remove the block (12).
PC750, 800-6 30-29

1
6. Lift the PTO assembly (13) and remove it. 1
4 PTO assembly: 500 kg
7. Lift the shaft (14) and remove it.
8. Remove the coupling (15). 2
9. Remove the plate (16). 3
INSTALLATION OF PTO
ASSEMBLY
procedures.
13
3 Bolt: 110.3 ± 12.2 Nm {11.25 ± 1.25 kgm}
2
3 Bolt:
277.05 ± 31.85 Nm {28.25 ± 3.25 kgm}
30-30 PC750, 800-6

1
DISASSEMBLY OF PTO
ASSEMBLY
1. Cover
Remove mounting bolts, then using bolt 1, re-
move case (3).
fl Check the number and thickness of the
shims, and keep in a safe place.
2. Gear assembly
Remove gear assemblies (5), (6), and (7).
fl If the gear assembly will not come out, re-
move nipple (8), then use a puller to remove
the gear assembly from the case.
3. Removal of bearing
Using puller 2, remove bearing from each gear.
PC750, 800-6 30-31

1
ASSEMBLY OF PTO
ASSEMBLY
fl Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
1. Bearings
Install bearings (9), (10), (11), (12), and (13) to
gears (5), (6), and (7).
2. Outer race at case end

Press fit outer race (14) to case (15).
3. Nipples, plug
Install nipples (8) and blind plug (16).
4. Gears
1) Install gears (5), and (7).
2) Install gear (6).
3) Rotate gears, check that each gear rotates
smoothly, then coat with red lead (minium),
and check tooth contact.
2 Bearing: Grease (G2-LI)
30-32 PC750, 800-6

1
5. Case
Fit gasket and install case (3).
2 Gasket: Gasket sealant (LG-1)
3 Bolt: 110.25 ± 12.25 Nm {11.25 ± 1.25 kgm}
fl After tightening the bolts, check that the

thickness of the gasket is the dimension
shown in the diagram on the right.
PC750, 800-6 30-33

1
Adjusting cover shim

fl Decide the thickness of the cover shim as fol-
lows.
1) Without fitting an O-ring, install cover (1),
rotate the gear in the direction of the arrow
(50 – 60 rpm), and tighten 2 bolts (18) uni-
formly to 19.6 Nm {2 kgm}.
2) Measure clearances F and G at two places
between case (3) and cover (1) with feeler
gauge 5.
3) Calculate clearance F + clearance G, and de-
termine the thickness of the shim according
to the following table.
Thickness, part number of

Overall
Clearance F + G
(mm) shim to use thick-
21N-30 21N-33 21N-38 ness of
–11250 –11260 –11270 shim
From To
(0.1mm) (0.2mm) (0.5mm) (mm)
0 0.12 1 1 0.3
0.12 0.32 2 0.4
0.32 0.52 1 0.5
0.52 0.72 1 1 0.6
0.72 0.92 1 1 0.7
0.92 1.12 1 1 1 0.8
1.12 1.32 2 1 0.9
1.32 1.52 2 1.0
1.52 1.72 1 2 1.1
1.72 1.92 1 2 1.2
1.92 2.12 1 1 2 1.3
2.12 2.32 2 2 1.4
2.32 2.52 3 1.5
2.52 2.72 1 3 1.6
2.72 2.92 1 3 1.7
2.92 3.12 1 1 3 1.8
3.12 3.32 2 3 1.9
3.32 3.52 4 2.0
3.52 3.72 1 4 2.1
3.72 3.92 1 4 2.2
3.92 4.12 1 1 4 2.3
4.12 4.32 2 4 2.4
4.32 4.52 1 2 4 2.5
6. Fit gasket and install cover (19).

2 Gasket: Gasket sealant (LG-1)
30-34 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1. Draining oil
Remove drain plug and drain oil from final drive
case.
6 Final drive case: Approx. 20 ¬
2. Put travel motor at bottom and set on block of

height approx. 350 mm.
3. Cover
Using forcing screws and eyebolts 1, remove
cover (1).
4. No. 3 carrier assembly

1) Remove thrust washer (50).
2) Using eyebolts 2, remove No. 3 carrier as-
sembly (2).
3) Disassemble No. 3 carrier assembly as fol-

lows.
i) Remove mounting bolts (3).
ii) Using tool J5, remove holder (4).
iii) Turn over carrier assembly (2) and set to

press, then using tool J6, pull out shaft
(5) and remove gear assembly (6).
PC750, 800-6 30-35

1
iv) Remove bearing (7) and spacer (8) from

gear (6).
fl If the parts are to be used again,
make match marks to prevent any
change in the combination with the
outer race.
v) Remove outer race (9) from gear (6).
5. No. 3 sun gear

1) Remove thrust washer (11) from No. 3 sun
gear (10).
2) Remove No. 3 sun gear (10).
6. No. 3 ring gear

Using eyebolts 3, remove No. 3 ring gear (12).
7. Hub assembly
1) Remove lock plate (13).
2) Using tool J4, remove nut (14).
30-36 PC750, 800-6

1
3) Using eyebolts 4, remove hub assembly (25)

together with bearing (16) from shaft (41).
4) Remove bearing (16) from hub (49).
5) Remove floating seal (17) from hub (49).

fl If the seal is to be used again, be careful not
to damage the contact surface, and keep in
a safe place.
6) Remove outer races (18).
8. Spacer
Remove spacer (19) from shaft (41).

sembly (20).
lows.
i) Knock pin (21) into shaft (22).
ii) Push shaft (22) from pin side to remove.
fl Remove the pin from the shaft.
iii) Pull out gear (23) from carrier (27), and

remove thrust washer (24) and bearing
(25).
iv) Remove thrust assembly (26) from car-
rier (27).
PC750, 800-6 30-37

1
10. No. 2 sun gear

Remove No. 2 sun gear (28).
11. No. 2 ring gear

Remove No. 2 ring gear (30).
12. Spacer
Remove spacer (31).

sembly (32).
lows.
i) Knock pin (33) into shaft (34).
ii) Remove shaft (34) from pin end.
fl Remove the pin from the shaft.
iii) Pull out gear (35) from carrier (36), then

remove thrust washer (37) and bearing
(38).
14. No. 1 ring gear

Remove No. 1 ring gear (39).
15. No. 1 sun gear

Remove No. 1 sun gear (40).
fl However, if the travel motor is removed, the
sun gear will fall off when it is put in the
posture for disassembly.
16. Thrust washer

Remove thrust washer (48) from travel motor.
17. Floating seal

Remove floating seal (17).
fl If the seal is to be used again, be careful not
to damage the contact surface, and keep in
a safe place.
30-38 PC750, 800-6

1
18. Travel motor assembly

Turn over shaft (41), and using eyebolts 7, re-
move travel motor assembly (42).
PC750, 800-6 30-39

1
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
fl 1) Clean all parts, check for dirt or damage,
and correct all dents and burrs.
2) Coat the bearings and surfaces of all parts
with engine oil before installing.
1. Travel motor assembly

1) Fit O-ring, and using eyebolts 7, install travel
motor assembly (42) to shaft (41).
fl The mounting direction for the motor on
the left and right final drive assemblies
is opposite, so be careful to distinguish
when installing.
2) Turn over travel motor and shaft assembly
and set on block (height: approx. 350 mm).
3) Press fit thrust washer (48) of travel motor.
After press fitting, confirm that thrust washer
(48) is in contact with motor (42).
Press fitting force:
225 – 2,646 N {23 – 270 kgf}
2. No. 1 sun gear

Install No. 1 sun gear (40).
3. No. 1 ring gear

Install No. 1 ring gear (39).
fl Set with the side with the cut outside cir-
cumference facing the motor.
4. Spacer
Install spacer (31).

1) Assemble No. 1 carrier assembly as follows.
fl There are the remains of the caulking
when the pin is inserted at the end face
of hole h at the side of the carrier, so
remove the caulked metal from the in-
side diameter of the hole before starting
to assemble.
i) Assemble bearing (38) to gear (35), put
thrust washer (37) in contact with both
ends, then set to carrier (36).
30-40 PC750, 800-6

1
ii) Align position of pin holes of carrier and

shaft, then tap with a plastic hammer to
install shaft (34).
fl When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
iii) Install pin (33).
fl Check that the pin groove and pro-
truding part of the pin are not fa-
tigued. If the pin is defective, replace
it with a new part.
fl When assembling the pin again,
avoid the position previously used
for caulking.
fl After inserting the pin, caulk the pin
portion (marked by arrows) of the
carrier.
fl After assembling the carrier assem-
bly, check that gear (35) rotates
smoothly.
2) Using eyebolts 6, install No. 1 carrier as-
sembly (32).
6. No. 2 sun gear

1) Press fit thrust washer (29) to No. 2 sun gear
(28).
2) Install No. 2 sun gear (28).
7. No. 2 ring gear

Install No. 2 ring gear (30).

i) Press fit thrust washer (44) to plate (43).
ii) Press fit thrust assembly (26) to carrier
(27).
PC750, 800-6 30-41

1
fl There are the remains of the caulking

when the pin is inserted at the end face
of hole h at the side of the carrier, so
remove the caulked metal from the in-
side diameter of the hole before starting
to assemble.
iii) Assemble bearing (25) to gear (23), put
thrust washer (24) in contact with both
ends, then set to carrier (27).
iv) Align position of pin holes of carrier and
shaft, then tap with a plastic hammer to
install shaft (22).
fl When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
v) Install pin (21).
fl Check that the pin groove and pro-
truding part of the pin are not fa-
tigued. If the pin is defective, replace
it with a new part.
fl When assembling the pin again,
avoid the position previously used
for caulking.
fl After inserting the pin, caulk the pin
portion (marked by arrows) of the
carrier. (See Step 5-1)-iii).)
fl After assembling the carrier assem-
bly, check that gear (33) rotates
smoothly.
sembly (20).
9. Spacer
Align protruding portion with protruding por-
tion of shaft (41), and install spacer (19).
fl Set the spacer with the shallow protruding
part facing the motor.
10. Hub assembly

1) Floating seal at shaft end
Using tool J1, install floating seal (17) to
shaft (41).
fl Remove all oil and grease from the O-
ring and O-ring contact surface, and dry
the parts before installing the floating
seal.
30-42 PC750, 800-6

1
fl After installing the floating seal, check

that the angle of the floating seal is
within 1 mm.
fl After installing the floating seal, coat the
sliding surface thinly with engine oil.
2) Inside bearing
Shrink fit bearing (16) to shaft (41), or use
tool J3 to install.
fl When using tool J3, see the drawing on the

right.
3) Outer race at hub end

Expand fit outer race (18) to hub (49), or use
tool J2 to install.
fl When using tool J2, see the drawing on
the right.
4) Floating seal at hub end

Using tool J1, install floating seal (17) to
hub (49).
fl For precautions and details of the tool,
see Step 10-1).
fl When turning over the hub, the floating
seal will be at the bottom, so install it
temporarily with several bolts 8.
5) Installation of hub assembly
Using eyebolts 4, install hub assembly (15)
to shaft (41).
PC750, 800-6 30-43

1
6) Outside bearing
Install bearing (16).
7) Install nut as follows.

i) Set tool J3 in position.
ii) Push bearing inner race portion with
specified force.
fl Pushing force:
34.3 – 38.2 kN {3.5 – 3.9 ton}
iii) Rotate hub assembly 2 – 3 times to settle
bearing.
iv) Measure dimension a in the condition

above.
v) Measure thickness b of nut (14) as an

individual part.
vi) Calculate a – b = c.
vii) Using tool J4, tighten nut (14) to a point
0
where dimension c = –0.1 mm.
30-44 PC750, 800-6

1
8) Install lock plate (13).

fl Install the lock plate as shown in the
diagram on the right.
2 Thread of mounting bolt:
Thread tightener (LT-2)
3 Mounting bolt, nut:
66.2 ± 7.3 Nm {6.75 ± 0.75 kgm}
11. No. 3 ring gear

1) Install O-ring to shaft end.
2) Using eyebolts 3, install No. 3 ring gear
(12).
fl Align the bolt holes.
fl Install the ring gear with the machined
outside circumference facing up (out-
side).

i) Using tool J7, press fit outer race (9) to
gear (46).
ii) Assemble bearing (7) and spacer (8) to

gear (46), and set to carrier (47).
fl Align the carrier and bearing and
spacer holes securely.
PC750, 800-6 30-45

1
iii) Expand fit shaft (5) or press fit with a

press.
fl Do not move the gear until the tip of
shaft (5) enters the carrier. Be par-
ticularly careful with the spacer.
fl After press fitting the pin, check that
the gear rotates smoothly.
fl When press fitting the shaft, be care-
ful of the angle of the shaft.
iv) Assemble holder (4) to shaft (5).
v) Tighten bolt (3).

2 Bolt: Thread tightener (LT-2)
3 Bolt:
927 ± 103 Nm {94.5 ± 10.5 kgm}
vi) Install thrust washer (50).

sembly (2).
fl Align the low portion (4 places) of spacer
(19) and shaft (14) with the carrier as-
sembly holder.
fl Align the bolt holes also.
13. No. 3 sun gear

1) Install thrust washer (11) to No. 3 sun gear
(10).
2) Install No. 3 sun gear (10).
fl Be careful not to get your fingers caught.
30-46 PC750, 800-6

1
14. Cover
Using eyebolts 1, install cover (1).
2 Mounting surface: Gasket sealant (LG-6)
2 Bolt: Thread tightener (LT-2)
3 Bolt: 980.1 ± 49.5 Nm {100 ± 5 kgm}
PC750, 800-6 30-47

1
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL OF REVOLVING
FRAME ASSEMBLY
1. Remove work equipment assembly from chas-
sis.
For details, see REMOVAL OF WORK EQUIP-
MENT ASSEMBLY.
2. Remove counterweight assembly.

For details, see REMOVAL OF COUNTERWEIGHT
ASSEMBLY.
3. Disconnect 4 grease tubes (1).
4. Leave 3 or 4 mounting bolts (2) each at front

and rear of revolving frame, and remove other
mounting bolts. 1
fl Start the engine and swing the revolving
frame while removing the bolts.
fl If you do not start the engine, remove the
swing motor and use a crane to swing the
revolving frame.
5. Disconnect swivel joint top pipes (3), (4), (5),

and (6).
6. Pull out pin (7), and move link (8) towards frame.
7. Revolving frame assembly 12

1) Fit wires to counterweight mounting frame
and boom mount, then sling revolving frame
assembly.
2) Remove remaining mounting bolts and lift
off revolving frame assembly (9).
fl Check that the wire is not damaged before
using it, and put protective material at the
corners.
fl The revolving frame will tilt towards the
operator’s cab, so adjust with a lever block.
4 Revolving frame assembly:

Approx. 19,000 kg
30-48 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
INSTALLATION OF REVOLVING
FRAME ASSEMBLY
removal.
1
2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
1,814 ± 98 Nm {185 ± 10 kgm}
2
2 Swing circle top surface:
Gasket sealant (LG-6)
PC750, 800-6 30-49

1
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
REMOVAL OF SWING
MACHINERY ASSEMBLY
1. Remove the swing motor assembly (1) referring
to the paragraph of “Removal of Swing Motor
Assembly”.
2. Drain oil from the swing machinery.
6 Oil in case: 24.5 ¬ approx. × 2
3. Lift the swing machinery assembly (2) tempo-

rarily, loosen the mounting bolt (3), screw in the
forcing screw, pull out the faucet joint portion
and remove the assembly.
4 Swing machinery assembly: 510 kg × 2
INSTALLATION OF SWING
MACHINERY ASSEMBLY
procedures.
3 Mounting bolt:
926.7 ± 102.9 Nm {94.5 ± 10.5 kgm}
• Oil Filling
oil filler port.
5 Oil amount in swing machinery case:

30 ¬ approx. × 2
30-50 PC750, 800-6

1
DISASSEMBLY OF SWING
MACHINERY ASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing 1
machinery case.
6 Swing machinery case: Approx. 24.3 ¬
2. Cover
Remove mounting bolts, then lift off cover (1).
CEP00205

1) Remove thrust washer (2).
2) Remove No. 1 sun gear (3). 3 2
CEP00206
3) Remove No. 1 carrier assembly (4).

4
CEP00207
4. Disassemble No. 1 carrier assembly as follows.

1) Push in pin (5) and knock out shaft (6) from
carrier (7).
fl After removing the shaft, remove pin (5).
2) Remove thrust washer (8), gear (9), bearing
(10), and thrust washer (11).
PC750, 800-6 30-51

1
5. Ring Gear
Lift the ring gear (12) and remove it.
6. No. 1 Sun Gear

1) Remove the thrust washer (13).
2) Remove the button (36) and the spacer (14).
3) Remove No. 1 sun gear (15).
3) Remove the thrust washer (16).

fl Remove No. 2 carrier assembly (17) be-
fore removing the washer.
7. No. 2 Carrier Assembly

Lift No. 2 carrier assembly (17) and remove it.
30-52 PC750, 800-6

1
8. Disassemble No. 2 carrier assembly as follows.

1) Push in pin (18), and knock out shaft (19)
from carrier (17). 19 22 17
fl After removing the shaft, remove pin 20
(18).
2) Remove thrust washer (20), gear (21), bear-
21
ing (22), and thrust washer (23).
23
18
CEP00213
9. Pinion shaft assembly

1) Remove bolt (24), then remove holder (25). 24
2) Remove gear (26). 26

25
CEP00214
3) Turn over case and pinion assembly, then

remove mounting bolts (28) of cover assem-
bly (27).
27
28
CEP00215
4) Turn over case and pinion assembly (29),

and set on press stand, then using push tool
F4, remove pinion shaft assembly (30) with
press.
fl Set a wooden block under the press, and
be careful not to damage the pinion shaft
assembly when removing it.
PC750, 800-6 30-53

1
10. Disassemble pinion shaft assembly as follows.

1) Using push tool 1, remove cover assembly
(27) and bearing (31) from shaft (32). 33
2) Remove oil seal (33) from cover (27).
27
31
32
27
CEP00218 CEP00219
11. Bearing
Using push tool, remove bearing (34) from case 35 34
(35).
CEP00220
30-54 PC750, 800-6

1
ASSEMBLY OF SWING
MACHINERY ASSEMBLY
Coat the sliding surfaces of all parts with engine
oil before installing.
1. Bearing
Using push tool F2, press fit bearing (31) to case
(35).
2. Cover assembly
1) Using push tool F1, press fit oil seal (33) to
cover (27).
2 Outside circumference of oil seal:
fl Be careful not to let the gasket sealant
(LG-6) get on the oil seal lip when press
fitting.
2) Fit cover assembly (27) to case (35), and

tighten mounting bolts (28). 27 28
2 Cover mounting surface:
35
2 Lip of oil seal: Grease (G2-LI)
fl Be careful not to let the gasket sealant
(LG-6) get on the oil seal lip when press
fitting.
CEP00223
3. Case assembly
1) Set case assembly (35) to shaft (32), then
using push tool 2, press fit bearing inner
race portion.
fl When setting the case assembly to the
shaft, be extremely careful not to dam-
age the oil seal.
PC750, 800-6 30-55

1
2) Bearing
Using tool F3, press fit bearing (34).
fl Push the bearing inner race and outer
race at the same time when press fitting.
Do not push only the inner race when
press fitting.
fl After press fitting the bearing, check that
the case rotates smoothly.
3) Gear, holder
Assemble gear (26), then fit holder (25) and 24
tighten bolt (24).
2 Mounting bolt: 26
Thread tightener (LT-2) 25
3 Mounting bolt:
343 – 427 Nm {35 – 43.5 kgm}
CEP00214
4. Assemble No. 2 carrier assembly as follows.

fl There are the remains of the caulking when 22 17
the pin is inserted at the end face of hole h
20
at the side of the carrier, so remove the
caulked metal from the inside diameter of
the hole before starting to assemble. 21
1) Assemble bearing (22) to gear (21), fit top
and bottom thrust washers (23) and (20) and
set gear assembly to carrier (17). 23
h
CEP00226
2) Align position of pin holes of shaft and car-

rier, then tap with a plastic hammer to in- 21 19
stall shaft (19).
fl When installing the shaft, rotate the plan-
etary gear, and be careful not to dam-
age the thrust washer.
3) Insert pin (18).
fl After inserting the pin, caulk the pin por-
tion of the carrier.
fl After assembling the carrier assembly, check
that gear (21) rotates smoothly.
18
CEP00227
30-56 PC750, 800-6

1
5. No. 2 Carrier Assembly

Lift No. 2 carrier assembly (17) and install it.
fl Adjust the positions of the 4 gear shaft ends
before installing it.
6. No. 2 Sun gear

1) Set the thrust washer (16).
fl Be sure to set the washer before installing
No. 2 carrier assembly (17).
2) Assemble No. 2 sun gear in No. 2 carrier.

3) Install the spacer (14) and the button (36).
4) Install the thrust washer (13).
7. Ring Gear
Lift the ring gear (12) and install it.
fl Apply gasket sealant to the periphery of the
oil level check hole a only.
2 Mating face of ring gear and case:
PC750, 800-6 30-57

1
8. Assemble No. 1 carrier assembly as follows.

fl There are the remains of the caulking when
the pin is inserted at the end face of hole h h 10 7
at the side of the carrier, so remove the
caulked metal from the inside diameter of 8
the hole before starting to assemble.
1) Assemble bearing (10) to gear (9), fit top
and bottom thrust washers (8) and (11) and
set gear assembly to carrier (7).
9 11
CEP00228
2) Align position of pin holes of shaft and car-

rier, then tap with a plastic hammer to in-
stall shaft (6). 5
fl When installing the shaft, rotate the plan-
etary gear, and be careful not to dam-
age the thrust washer.
3) Insert pin (5).
fl After inserting the pin, caulk the pin por-
tion of the carrier.
fl After assembling the carrier assembly, check
that gear (9) rotates smoothly. 9 6
CEP00229

Install No. 1 carrier assembly (4).
4
CEP00207
10. No. 1 sun gear

1) Assemble No.1 sun gear (3) to carrier as-
sembly. 3 2
2) Install thrust washer (2).
CEP00206
30-58 PC750, 800-6

1
11. Cover
Install cover (1).
2 Cover mounting surface:
Gasket sealant (LG-6) 1
3 Mounting bolt:
1st pass: 98 Nm {10 kgm}
2nd pass: 105 ± 5°
CEP00205
12. Refilling with oil

Tighten drain plug and add oil through oil filler.
5 Swing machinery case: Approx. 24.3 ¬
PC750, 800-6 30-59

1
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL OF SWING CIRCLE

ASSEMBLY
1. Remove revolving frame assembly.
For details, see REMOVAL OF REVOLVING
FRAME ASSEMBLY.
2. Remove grease tubes (1).
3. Remove mounting bolts (2). 1
4. Pass round bar through revolving frame mount-

ing bolt holes, fit wire, then lift off swing circle
assembly (3). 2
4 Swing circle assembly: 1,263 kg
5. Remove seal (4).
CIRCLE ASSEMBLY
removal.
1
3 Mounting bolt:
1,715 ± 195 Nm {175 ± 20 kgm}
2
2 Swing circle mounting surface
: Gasket sealant (LG-6)
fl Amount of grease (G2-LI) in oil bath:
Approx. 65 ¬
fl Coat inside teeth with grease (G2-LI).
fl Apply about 10 ¬ of grease (G2-LI) to the
internal tooth.
fl Install so that the inner race soft zone is
facing the left side of the chassis.
30-60 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY TRACK SHOE
REMOVAL OF TRACK SHOE

ASSEMBLY
1. Positioning master pin
fl Move the master pin so that it is midway
between the idler and the carrier roller. The
track shoe is opened to the rear, so be sure
that there is enough space.
2. Loosen track shoe tension. 1

 Never loosen lubricator (1) more than one
turn.
fl If the track tension is not relieved even when
the lubricator is loosened, move the machine
backwards and forwards.
3. Using tool M, pull out master pin.
4. Fit block or hydraulic jack 1 (10 ton) under shoe

at idler end, then remove guide pin 2.
2
5. Raise tip of track shoe with crane, and move

machine slowly to rear to open track shoe as-
sembly (3).
PC750, 800-6 30-61

1
DISASSEMBLY AND ASSEMBLY TRACK SHOE
INSTALLATION OF TRACK
SHOE ASSEMBLY
removal.
1
fl Adjust the track shoe tension.
Adjusting track shoe tension.
3 Lubricator:
73.5 ± 14.7 Nm {7.5 ± 1.5 kgm}
2
fl Assemble spacer (4) and washer (5) to the
link, connect to bottom link, then install guide
pin.
30-62 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY ONE LINK
DISASSEMBLY OF ONE LINK

IN FIELD
1. Using two bolts (2), install tool N1 (adapter,
guide, bolt) to link (1).
fl It is also possible to use two track bolts for
bolt (2).
2. Assemble tool N2 (pump, cylinder 1471 kN {150t})

and tool N3 (frame, rod, adapter, bolt x 1, eye-
bolt), then raise chassis and set on track.
3. Insert rod of tool N4 from cylinder end, and

install with two nuts.
fl Pass the rod through the hole in link (1) to
install.
4. Set tool N5 (adapter, guide, pusher) in position,

then apply hydraulic pressure and remove pin
(3).
When the cylinder reaches the end of its stroke,
insert extension N5 between the adapter and
guide, and repeat the operation.
PC750, 800-6 30-63

1
5. Set tool N6 (294 kN {30ton} puller) and spacer 1

to center of roller tread of link to be disas-
sembled, then apply hydraulic pressure to puller
and open link 5 – 6 mm.
30-64 PC750, 800-6

1
FIELD ASSEMBLY OF ONE

LINK
1. Assemble link sub-assembly.
1) Set tool N7 to end face of link, then press fit
bushing (1).
2) Set tool N7 to end face of link (pin end), and
press fit pin (2).
2. Set link sub-assembly (3) on link to be connected.
3. Set link (4) on opposite side, and support with

tool N8 (guide).
4. Set tools N9 and N10 in same way as for opera-

tion to remove pin, then use tool N9 (adapter,
extension, guide, adapter, bolt) for press fitting
pin, and tool N10 (extension, guide, adapter,
bolt) for press fitting bushing, and press fit in
turn.
PC750, 800-6 30-65

1
5. Use tool N13 (294 kN {30t} puller) in same way

as when disassembling, and push open link (5)
at bushing end.
6. Set link (6) at pin end to link (5) at bushing end,

connect with tool N11 (guide), then remove tool
N13 (puller).
7. Set tool N9 at pin (7) end, then use tool N12

(adapter, bolt, and guide) to press fit pin (7).
2 Pin press-fitting hole in link:

30-66 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY IDLER
REMOVAL OF IDLER
ASSEMBLY
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE AS-
SEMBLY.
2. Remove idler assembly (1).

fl Pull out the idler assembly, then lift off the
idler and adjustment cylinder.
4 Idler assembly: 500 kg
INSTALLATION OF IDLER
ASSEMBLY
removal.
PC750, 800-6 30-67

1
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove plug and drain oil.
6 Idler : Approx. 550 – 630 cc
2. Set idler assembly (1) on block 1, remove bolt

and nut (2), then remove support (3).
3. Remove floating seal (4).
4. Turn over idler assembly, remove bolt and nut

(5), then remove support (6).
5. Remove shaft (8) from idler.
6. Remove floating seal (4) from idler (7).
30-68 PC750, 800-6

1
7. Remove bushings (9) and (10) from idler.
8. Remove floating seals (4) from supports (3) and

(6).
PC750, 800-6 30-69

1
ASSEMBLY OF IDLER
ASSEMBLY
1. Using tool L2, assemble floating seals (4) to sup-

ports (6) and (3).
2. Using tool L1, press fit bushings (10) and (9) to

idler.
3. Using tool L2, assemble floating seal (4) to idler.
4. Turn over idler and using tool L2, assemble float-

ing seal (4).
30-70 PC750, 800-6

1
5. Install shaft (8) to idler.

fl Assemble the shaft so that the direction of
the oil filler plug is as follows.
• Right side of machine: Facing outside
• Left side of machine: Facing inside
6. Assemble support (6) to shaft.

fl Align the groove in the support with the
groove in the shaft when assembling.
7. Install bolt and nut (5), and secure support (6).
8. Turn over idler, and assemble support (3) to

shaft.
fl Align the groove in the support with the
groove in the shaft when assembling.
9. Install bolt and nut (2), and secure support (3).
10. Using tool J3, add oil to specified level, then

tighten plug.
5 Idler: 550 – 630 cc (GO140B)

3 Plug: 210.7 ± 29.4 Nm {21.5 ± 3 kgm}
PC750, 800-6 30-71

1
DISASSEMBLY AND ASSEMBLY IDLER ADJUSTMENT CYLINDER
DISASSEMBLY OF IDLER
ADJUSTMENT CYLINDER
ASSEMBLY
1. Remove plunger assembly (1).
2. Remove snap ring (3), then remove packing (4),

backup ring (5), and wear ring (6) from plunger
(2).
3. Remove dust seal (7).
ASSEMBLY OF IDLER
ADJUSTMENT CYLINDER
ASSEMBLY
1. Install wear ring (6) to plunger (2).
2. Assemble backup ring (5) and packing (4) to

plunger (2), and install snap ring (3).
3. Fill inside with grease (G2-LI), then assemble

plunger assembly (1) in piston.
4. Install dust seal (7).
30-72 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
REMOVAL OF RECOIL SPRING

ASSEMBLY
fl The coil portion of the recoil spring assembly is
hooked on the rib inside the track frame, so
prepare a special tool for disassembly.
1. Remove track shoe assembly.

SEMBLY.
2. Remove idler assembly.
For details, see REMOVAL OF IDLER ASSEM-
BLY.
3. Recoil spring assembly

1) Remove No. 2 and No. 3 track roller assem-
blies.
For details, see REMOVAL OF TRACK
ROLLER ASSEMBLY.
2) After removing track roller assembly, install
tool 1.
fl When making tool 1, see Fig. 1.
fl Lower the track frame on top of the track
shoe.
3) Using eyebolts (Thread dia.=16mm,
Pitch=2.0mm), pull out recoil spring as-
sembly (1) and lift off.
4 Recoil spring assembly: 250 kg
INSTALLATION OF RECOIL
SPRING ASSEMBLY
removal.
1
fl To check that the spring is securely fitted
inside the track frame, check through the
side hole on the inside (at the 5th track roller
from the front).
PC750, 800-6 30-73

1
Fig. 1 (for tool 1)
30-74 PC750, 800-6

1
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Set recoil spring assembly (1) to tool M3.
 The recoil spring is under large installed load,
so be sure to set the tool properly. Failure to
do this is dangerous.
fl Installed load of spring: 490 kN {50 ton}
2. Apply hydraulic pressure slowly to compress

spring, then remove lock plate, and remove nut
(2).
3. Release hydraulic pressure gradually to relieve

tension of spring, then remove recoil spring as-
sembly (1) from tool M3.
4. Remove rear pilot (4) and rod (5) from spring

(3).
PC750, 800-6 30-75

1
ASSEMBLY OF RECOIL SPRING

ASSEMBLY
1. Install tool D1 to tip of rod (5).
fl Tool M4 is to prevent damage to the thread
when inserting the rear pilot.
2. Install rod (5) to spring (3).

Assemble rear pilot (4), and set to tool M3.
The recoil spring is under large installed load,
so be sure to set the parts properly. Failure
to do this is dangerous.
3. Apply hydraulic pressure slowly to compress

spring so that installed length of spring is stan-
dard dimension.
fl Installed length “a” of spring: 1,290 mm
4. Fit nut (2) and secure with lock plate.
5. Release hydraulic pressure gradually to relieve

tension of spring, then remove recoil spring as-
sembly (1) from tool M3.
30-76 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL OF CARRIER
ROLLER ASSEMBLY
1. Loosen the track shoe a bit referring to the para-
graph of “Tension Adjustment of Track Shoe”
in Testing and Adjusting.
2. Use the hydraulic jack 1 to push up the track

shoe.
3. Remove 4 pieces of the mounting bolt (1).
4. Lift the carrier roller assembly (2) and remove it.

fl Take out the carrier roller assembly as far as
it does not drop.
4 Carrier roller assembly: 52 kg
INSTALLATION OF CARRIER
ROLLER ASSEMBLY
procedures.
3 Carrier roller mounting bolt:
549 ± 58 Nm {56 ± 6 kgm}
PC750, 800-6 30-77

1
DISASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Remove the plug and drain oil.
6 Carrier roller assembly:

300 – 350cc approx.
2. Set the carrier roller assembly on the press base.

fl Since the assembly will drop if the support
(2), the shaft (3) and the roller (4) are re-
moved from the roller (1), set a pedestal
below the roller.
3. Push the shaft end face with the press and in-
stall the assembly of the support (2), the shaft
(3) and the roller.
fl Remove the floating seal (5) from the sup-
port (2).
4. Push the end face of the shaft (3) and remove
the shaft (3), the bearing (6) and the spacer (8)
from the roller (4).
5. Remove the assembly of the roller (4) and the

floating seal (5) on the support (2).
6. Remove the floating seal (5) from the support
(2).
7. Remove the bearing (6) from the support (2).
8. Remove the floating seal (5) from the roller (4).
9. Remove the bearing (6) from the shaft (3) by

using the tool L4.
10. Remove the bearing outer race (7) from the sup-
port (2).
30-78 PC750, 800-6

1
ASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Press fit the bearing outer race (7) in the both
sides of the support (2) by using the tool L3.
2. Press fit the bearing (6) in the shaft (3) by using
the tool L4.
3. Mount the floating seal (5) on the roller (4) by
using the tool L6.
fl Make sure that the seal is inclined less than
1mm.
fl Clean the O-ring and the O-ring contacting
surface to degrease them completely and
dry them.
4. Set the roller (4), on which the floating seal (5)
was set, on the tool L5.
5. Press fit the shaft (3), to which the bearing (6)
was assembled, in the roller (4).
6. Assemble the floating seal (5) in the support (2)
and mount them so that the bearing (6) aligns
to the bearing outer race (7).
7. Insert the spacer (8) in the shaft.
8. Press fit the bearing (6) in the shaft (3).
9. Mount the floating seal (5) on the support (2).
10. Press fit the roller, in which the floating seal (5)
was assembled, in the shaft (3).
fl Press fit the roller (4) to the shaft end face
and press fit the roller finally by using the
tool L5.
fl Secure more than 18 ton of press fitting force
between the shaft and each roller.
11. Assemble the carrier roller assembly (1) and fill

it with oil.
5 Lubricating oil: 300 – 350cc (GO140)
12. After filling it with oil, plug the assembly.

3 Plug: 206 ± 49 Nm {21 ± 5 kgm}
PC750, 800-6 30-79

1
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL OF TRACK ROLLER

ASSEMBLY
1. Loosen track shoe tension.
SEMBLY.
2. Remove track roller guard (1).
4 Track roller guard: 170 kg
3. Using work equipment, push up track frame on

side which is to be removed.
 After jacking up the chassis, set a block on
the track shoe.
4. Using tool L12, remove track roller assembly

(2). 1
4 Track roller assembly (S flange): 140 kg
INSTALLATION OF TRACK
ROLLER ASSEMBLY
removal.
13 Roller mounting bolt:

137.2 ± 98 Nm {140 ± 10 kgm}
30-80 PC750, 800-6

1
DISASSEMBLY OF TRACK
ROLLER ASSEMBLY
1. Remove plug and drain oil.
fl Rotate the shaft while draining the oil.\
6 Track roller: Approx. 420 – 480 cc
2. Remove pin (1), then remove collar (2).

3
3. Remove floating seal (3) from collar (2) and roller 3
(4).
4. Pull out roller (4) from shaft (5).

fl It is filled with 280 – 310 cc. of oil, so drain 4
the oil at this point or lay a cloth to prevent
the area from becoming dirty.
1
2 CEP00085 CEP00086
5. Remove floating seal (6) on opposite side from

roller (4) and collar (8).
5
6
4
4
CEP00087 CEP00088
6. Remove pin (7), then remove collar (8) from

shaft (5).
9, 10
7. Remove bushings (9) and (10) from roller (4). 5
4
7 CEP00089 CEP00090
PC750, 800-6 30-81

1
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
1. Using tool L10, press fit bushings (9) and (10) to
roller (4).
2. Assemble collar (8) to shaft (5), and install pin

(7).
3. Using tool L9, install floating seal (6) to shaft

(5).
fl When assembling the floating seal, clean the
contact surface of O-ring (6c) and floating
seal (6a), remove all grease and oil, and dry
it. Make sure that no dirt or dust sticks to
the contact surface of the floating seal.
fl After inserting the floating seal, check that
the angle of the seal is less than 1 mm and
that the protrusion of the seal is within a
range of 5 – 7 mm.
4. Using tool L9, install floating seals (6) and (3) to

roller (4).
fl For details of the precautions when install-
ing floating seals (6b) and (6d), and (3b) and 5
(3d), see the precautions marked fl for Step
3.
5. Assemble shaft (5) to roller (4). 4
CEP00096
6. Turn over roller (4) and shaft (5) assembly.
7. Using tool L9, install floating seal (3) to collar

(2). 4
fl For details of the precautions when install-
ing floating seals (3a) and (3c), see the pre-
cautions marked fl for Step 3.
5
CEP00097
30-82 PC750, 800-6

1
8. Assemble collar (2) to shaft (5), and install pin

(1). 1
2
5
CEP00099
9. Using tool L11, apply standard pressure to roller

oil filler port, and check for leakage of air from
seal.
fl Standard pressure: 0.1 MPa {1 kg/cm2}
fl Method of checking
The standard pressure shall be maintained
for 10 seconds and the indicator of the gauge
shall not go down.
10. Using tool L11, fill track roller assembly with oil,
then tighten plug (11).
5 Track roller oil: 280 – 310 cc (EO30-CD)

3 Plug: 14.7 ± 4.9 Nm {1.5 ± 0.5 kgm}
11
CEP00202
PC750, 800-6 30-83

1
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK ASSEMBLY
 Swing the frame to bring the hydraulic tank to
the intermediate position between the left and
the right track shoes.
fl Place counter marks on all hoses before discon-
necting them.
fl Stop all disconnected tubes and hoses with blind
plug.
1. Drain oil from the hydraulic tank.
6 Hydraulic tank : 650 ¬
2. Remove the control valve cover (1).
4. Remove 3 pieces of the wiring clamp (3) and

disconnect the wiring connector (4).
5. Loosen 3 pieces of the mounting bolt (5) of the

pilot relief valve assembly and remove the valve
assembly from the hydraulic tank without dis-
connecting the hose.
30-84 PC750, 800-6

1
6. Loosen the drain filter assembly bracket bolt (6)

and remove it from the hydraulic tank.
7. Loosen the PTO lubricating oil filter bracket bolt
(7) and remove it from the hydraulic tank.
8. Disconnect the return filter inlet hose (8) and

the outlet hose (9) from the control valve.
9. Disconnect the hose (10) from the oil cooler.

10. Disconnect the hoses (11) and (12) from the re-
turn filter to the oil cooler.
11. Disconnect the suction tube (13) below the hy-

draulic tank.
PC750, 800-6 30-85

1
12. Lift the hydraulic tank assembly (14) and re-

move it.
4 Hydraulic tank assembly: 474 kg
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
procedures.
2 Mounting bolt: Liquid glue (LT-2)
3 Hydraulic tank mounting bolt:
549 ± 58 Nm {56 ± 6 kgm}
• Filling (hydraulic tank) with oil

Circulate oil throughout the pipe and then check
the oil level again.
• Air Bleeding
Bleed air referring to the paragraph of “Bleed-
ing Air from Each Part” in Testing and Adjust-
ing.
30-86 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY MAIN PUMP
REMOVAL OF MAIN PUMP

(NO. 1 PUMP) ASSEMBLY
Lower the work equipment completely to the
Disconnect the (–) terminal of the battery.
fl Attach a tag to each hose so that it can be con-
nected to the correct position.
1. Remove the strainer of the hydraulic tank and
stop oil flow by using the tool S.
fl When the tool S is not used, remove the
drain plug and drain oil from the hydraulic
tank and the pipes.
6 Hydraulic tank: 500 ¬ approx.
2. Open the engine hood and the pump rear cover

and remove the pump upper cover.
3. Remove the TVC solenoid connector (1).
4. Disconnect the hose (2).
7. Disconnect the hoses (9), (10), (11), (13) and (14).
8. Disconnect the suction tube (12).
9. Lift the main pump (No. 1 pump) assembly tem-

porarily, remove the mounting bolt and remove
the assembly.
4 Main pump assembly: 165 kg
PC750, 800-6 30-87

1
INSTALLATION OF MAIN
PUMP (NO. 1 PUMP)
ASSEMBLY
procedures.
• Filling (the hydraulic tank) with oil

oil filler port, start the engine to circulate oil
throughout the pipes and check the oil level
again.
• Bleeding Air
fl Bleed air from each part referring to the para-
graph of “Testing and Adjusting”.
30-88 PC750, 800-6

1

(NO. 2 PUMP)
 Lower the work equipment to touch the ground
completely and stop the engine. After that, slowly
loosen the cap of the hydraulic oil tank to re-
lease the inside pressure of the hydraulic oil
tank.
 Separate the (–) terminal of the battery.
fl Put tags, etc. to each piping so that the mount-
ing position may not be mistaken.
1. Remove the hydraulic oil tank strainer and stop
the oil using the tool S.
fl In case the tool S is not used, remove the
drain plug to drain oil from the inside of the
hydraulic oil tank and from the inside of the
piping.
6 Hydraulic oil tank: Approx. 500 ¬
2. Open the engine hood and the rear cover of the

pump. After that, remove the upper cover of the
pump.
3. Separate the hoses (1), (2), (3) and (4).
4. Separate the hoses (5) and (6) and suction tube

(7).
5. By the hanging bolt, temporarily hang the main

pump (No. 2 pump) assembly (8) and remove
the mounting bolt to remove the pump.
4 Main pump assembly: 150 kg
PC750, 800-6 30-89

1
PUMP (NO. 2 PUMP)
ASSEMBLY
• Installation shall be made in the reversed proce-
dure of the removal procedure.
• Filling the oil (Hydraulic oil tank)

fl Fill the oil to the stipulated level from the oil
filler port, start the engine to circulate the oil
inside the piping and, after that, re-check
the oil level.
• Air bleeding
fl Carry out air bleeding of each section refer-
ring to the section “Testing and adjusting”.
30-90 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL

INPUT SHAFT OIL SEAL
1. Remove main pump assembly.
For details, see REMOVAL OF MAIN PUMP AS-
SEMBLY.
2. Remove cover (1).

fl Be careful not to lose shims (2) and (3).
3. Remove oil seal (4) from cover (1).
PUMP INPUT SHAFT OIL SEAL
removal.
1
2 Lip of oil seal: Grease (G2-LI)
2 Coat the outside circumference of the oil
seal thinly with grease (G2-LI), then press
fit.
fl Using tool 1, press fit oil seal (4).
PC750, 800-6 30-91

1
DISASSEMBLY AND ASSEMBLY CONTROL • PTO LUBRICATION PUMP
REMOVAL OF CONTROL • PTO

LUBRICATION PUMP
ASSEMBLY
tank.
fl Put tags, etc. to each piping so that the mount-
ing position may not be mistaken.
1. Remove the hydraulic oil tank strainer and stop
the oil using the tool S.
fl In case the tool S is not used, remove the
drain plug to drain oil from the inside of the
hydraulic oil tank and from the inside of the
piping.
6 Hydraulic oil tank: Approx. 500 ¬
2. Open the rear cover of the pump.
3. Remove the suction hose and tube.
4. Separate the delivery port hoses (3) and (4).
5. Remove the control • PTO lubrication pump as-

sembly (6).
4 Pump assembly: 35 kg
INSTALLATION OF CONTROL •
PTO LUBRICATION PUMP
ASSEMBLY

the oil level.
• Air bleeding
fl Carry out air bleeding of each section refer-
ring to the section “Testing and adjusting”.
30-92 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
DISASSEMBLY OF MAIN
RELIEF VALVE ASSEMBLY
1. Remove sleeve assembly (1) from sleeve (2).
2. Remove springs (3) and (4), pistons (5) and (6),

and sleeve (7).
3. Disassembly of sleeve assembly (1)

fl Do not disassemble except when replacing
parts. Measure the protrusion of sleeves (9)
and (12) when disassembling.
fl Loosen locknut (8), and remove sleeve (9)
and piston (10).
fl Loosen locknut (11), and remove sleeve (12),
spring (13), and piston (14) from sleeve (15).
ASSEMBLY OF MAIN RELIEF

VALVE ASSEMBLY
1. Assembly of sleeve assembly (1)
fl Set sleeves (12) and (9) to the protrusion
measured when disassembling. After install-
ing to the control valve, adjust the relief pres-
sure.
For details, see TESTING AND ADJUSTING.
1) Assemble piston (14) and spring (13) to
sleeve (15), then screw in sleeve (12) and
tighten locknut (11).
3 Locknut:
107.8 ± 14.7 Nm {11 ± 1.5 kgm}
2) Assemble piston (10) and sleeve (9) to sleeve
(12), and tighten locknut (8).
3 Locknut:
85.75 ± 7.35 Nm {8.75 ± 0.75 kgm}
2. Assemble sleeve (7), pistons (6) and (5), and

springs (4) and (3) to sleeve (2).
3. Install sleeve assembly (1).

3 Sleeve: 186.2 ± 9.8 Nm {19 ± 1 kgm}
PC750, 800-6 30-93

1
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL OF CONTROL
VALVE ASSEMBLY
tank.
 Referring to the section “Releasing the remain-
ing pressure from the hydraulic circuit” in the
“Testing and adjusting”, release the remaining
pressure from the hydraulic circuit.
fl Put the counter mark before separating the hose
and tube.
fl Put the blinding plug to the hose and tube.
1. Remove the control valve cover (1).
3. Separate the PPC hose (3) of the pilot change

over valve and the hose (4) between the control
valve. After that, remove the valve assembly (5).
4. Remove the tubes (6) and (7) between the main

pump and remove the tube (8) between the 4-
spool control valve and the 5-spool control valve.
30-94 PC750, 800-6

1
fl 4-spool control vale

5. Separate the 14 pcs. of the PPC hoses (9).
6. Separate each tube of the travel (10), boom (11),

bucket (12) and arm (13).
7. Separating the lower side back pressure com-
pensation valve hose
Separate the tube (14) between the 5-spool con-
trol valve.
8. Temporarily hang the 4-spool control valve and

remove the 3 pcs. of the mounting bolts (15) to
remove the control valve assembly (16).
4 4-spool control valve assembly, RH:

250 kg
fl 5-spool control vale

9. Separate the LH swing motor hose (17).
10. Separate the RH swing motor hose (18).
11. Remove the tube clamp (19) and tube (20).
12. Remove the piping brackets (21) and (22).
13. Separate each tube of the boom (23), swing (24),

arm (25), bucket (26) and travel (27).
14. Separating the lower side back pressure com-
pensation valve hose
Separate the tube (28) between the 4-spool con-
trol valve.
15. Separate the 16 pcs. of the PPC hoses (29).
PC750, 800-6 30-95

1
16. Temporarily hang the 5-spool control valve and

remove the 3 pcs. of the mounting bolts (30) to
remove the control valve assembly (16).
4 5-spool control valve assembly, RH:

250 kg
INSTALLATION OF CONTROL
VALVE ASSEMBLY
fl Install the tube (1) and adjust the mounting po-

sition of the valve. After that, fasten the valve
assembly mounting bolt (2).
3 Control valve assembly mounting bolt:
279 ± 29 Nm {28.5 ± 3 kgm}
fl Referring to the section “Testing and adjusting”,

confirm the hydraulic pressure of the work equip-
ment circuit, travel circuit and swing circuit and
confirm the speed.

the oil level.
30-96 PC750, 800-6

1
DISASSEMBLY OF CONTROL
VALVE ASSEMBLY
(WORK EQUIPMENT)
fl The operation described below is for the right 4-
spool control valve (with straight-travel valve),
but the procedure is basically the same for the
left 5-spool control valve also.
1. Remove mounting bolts, then remove straight-

travel valve assembly (2).
2. Disassemble straight-travel valve assembly as
follows.
1) Remove cover (3).
2) Pull out plug (4), and remove backup ring
(5).
3) Remove sleeve (6), and pull out piston (7),
spool (8), and spring (9).
4) Remove plug (10), and pull out spring (11)
and check valve (12).
5) Loosen (13) and remove sleeve (14).
3. Remove spring (15) and check valve (16).
4. Remove seat (17), spring (18), and check valve
(19).
5. Pull out spool from valve body as follows.
1) Remove case (20), then remove springs (21)
and (22), and retainer (23).
2) Pull out spool (24) from valve body.
6. Pull out spool from valve body as follows.
1) Remove case (25), then remove springs (26)
and (27), and retainer (23).
2) Pull out spools (28), (29), and (30) from valve
body.
7. Remove orifice (31) and jet sensor relief valve
(32).
8. Remove suction-safety valves (33) and (34).
9. Remove suction valve (35).
10. Remove 2-stage safety valve (36).
11. Remove main relief valve (37).
30-98 PC750, 800-6

1
PC750, 800-6 30-99

1
ASSEMBLY OF CONTROL
VALVE ASSEMBLY
(WORK EQUIPMENT)
fl The operation described below is for the right 6. Install spool to valve body as follows.
4-spool control valve (with straight-travel 1) Assemble spools (30), (29), and (28) to
valve), but the procedure is basically the valve body.
same for the left 5-spool control valve also. 2) Assemble retainer (23), and springs (26)
fl Coat the sliding surface with engine oil when and (27), then fit O-ring and install case
assembling. (25).
7. Install spool to valve body as follows.
1. Fit O-ring and install main relief valve (37). 1) Assemble spool (24) to valve body.
3 Main relief valve: 2) Assemble retainer (23), and springs (22)
320.95 ± 46.55 Nm {32.75 ± 4.75 kgm} and (21), then fit O-ring and install case
(20).
2. Fit O-ring and install 2-stage safety valve
(36). 8. Assemble check valve (19), spring (18), and
3 2-stage safety valve : seat (17) to valve body.
225.4 ± 9.8 Nm {23 ± 1 kgm}
9. Install check valve (16) and spring (15).
3. Fit O-ring and install suction valve (35).
3 Suction valve: 10. Assemble straight-travel valve as follows.
225.4 ± 9.8 Nm {23 ± 1 kgm} 1) Fit O-ring and backup ring (38), then in-
stall sleeve (14), and tighten nut (13).
4. Fit O-ring and install suction-safety valves 2) Assemble check valve (12) and spring
(34) and (33). (11), then fit O-ring and backup ring (39)
3 Suction-safety valve: and install plug (10).
225.4 ± 9.8 Nm {23 ± 1 kgm} 3) Assemble spring (9), spool (8), and pis-
ton (7) to valve body, then fit O-ring and
5. Fit O-ring and install jet sensor relief valve install sleeve (6).
(32) and orifice (31). 4) Fit backup ring (5) and install plug (4).
3 Jet sensor relief valve : 5) Install cover (3).
186.2 ± 9.8 Nm {19 ± 1 kgm}
3 Orifice: 11. Fit O-ring, then fit straight-travel valve as-
151.9 ± 24.5 Nm {15.5 ± 2.5 kgm} sembly (2), and tighten mounting bolts (1).
30-100 PC750, 800-6

1
PC750, 800-6 30-101

1
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
REMOVAL OF SOLENOID
VALVE ASSEMBLY
tank.
fl Put the counter mark before separating the PPC
circuit hose.
fl Put the blinding plug to the separated tube and
hose.
1. Boom damping valve

1) Remove the tool box (1) positioned in front
of the hydraulic oil tank.
2) Separate the wiring connectors (2) (V9 and
V10).
3) Remove the nut (3) and remove the coil (4).
fl V9 and V10:
Boom damping solenoid valve
2. Straight traveling valve, 2-stage boom head safety

valve, travel speed change over valve, main 2-
stage relief valve and CO canceling valve
1) Make the access from the hole (1) of the
lower surface of the revolving frame.
2) Remove the clips (5) and (6).
3) Separate the wiring connectors (2) (V02, 03,
05, 06 and 07).
4) Remove the bolt (3) and remove the coil (4).
fl V2 = Main 2-stage relief valve
V3 = Straight traveling valve
V5 = 2-stage boom head safety valve
V6 = Travel speed change over valve
V7 = CO canceling valve
3. Swing parking brake valve

2) Remove the clip (5).
3) Separate the wiring connector (2) (V04).
fl V4 = Swing parking brake valve
30-102 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
4. Swing priority change over valve

2) Remove the clip (5).
3) Separate the wiring connector (2) (V04).
fl V1 = Swing priority change over valve
INSTALLATION OF SOLENOID
VALVE ASSEMBLY
fl Pay attention so that dust, etc. shall not adhere
to the coil insertion section.
PC750, 800-6 30-103

1
DISASSEMBLY AND ASSEMBLY BOOM DAMPING VALVE
REMOVAL OF BOOM
DAMPING VALVE ASSEMBLY
tank.
fl Release the remaining pressure from the PPC
circuit.
fl Put the blinding plug to the separated hose.
1. Remove the tool box (1) positioned in front of

the hydraulic oil tank.
2. Separate the solenoid wiring connectors (2) (V9

and V10).
3. Separate the 4 pcs. of the hoses (3) and (4)
between the solenoid valve and the damping
valve.
fl Separate the hose between the damping
valve and the PPC valve, RH and separate
the hose between the damping valve and
the relay joint.
4. Remove the mounting bolt to remove the damp-
ing valve assembly (5).
INSTALLATION OF BOOM
DAMPING VALVE ASSEMBLY
• Air bleeding
Carry out air bleeding of the PPC piping circuit
referring to the section “Air bleeding of each
section” in the “Testing and adjusting”.
30-104 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY SWING MOTOR
REMOVAL OF SWING MOTOR

ASSEMBLY
completely and stop the engine.
 1) Referring to the section “Releasing the re-

maining pressure from the hydraulic circuit
on PPC valve installed machines” in the “Test-
ing and adjusting”, release the remaining
2) Slowly loosen the cap of the hydraulic oil
tank to release the inside pressure of the
hydraulic oil tank.
fl Center side of the machine body
1. Separate the hoses (1) and (2) from the control
valve and separate the hoses (3) and (4) to the
swing motor positioned in the front section of
the machine body.
2. Separate the swing parking brake hose (5) and
the drain hose (6).
3. Remove the U-bolt (7) of the oil gauge tube,
remove the bolt (8) and remove the bracket (9).
fl Front side of the machine body

1. Separate the hoses (10) and (11) from the swing
motor positioned in the central section of the
machine body.
2. Separate the swing parking brake hose (12) and
the drain hose (13).
3. Separate the swivel joint section hose (14).
4. Remove the bolt (15) and remove the bracket
(16).
5. Loosen the 4 pcs. of the bolt (17) and remove
the swing motor assembly (18)/(19).
4 Swing motor assembly: 57 kg × 2
MOTOR ASSEMBLY
3 Swing motor assembly mounting bolt:
926.7 ± 102.9 Nm {94.5 ± 10.5 kgm}
• Filling the oil
filler port and circulate the oil inside the pip-
ing. After that, re-check the oil level.
fl Fill the quantity of the oil which leaked when
the motor assembly was removed.
PC750, 800-6 30-105

1
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVEL

JOINT
tank.
1. Separate the lower section hoses (1), (2), (3) and

(4) of the swivel joint.
2. Separate the upper section hoses (5), (6), (7)

and (8) of the swivel joint.
3. Pull out the pin (9) and shift the link (10) to the
direction of the frame side.
fl Separate the hose (12) between the swing
motor.
4. Temporarily hang the swivel joint assembly.

fl Use the hole of the split flange bolt.
5. Removing the lower side mounting bolt, hang

the swivel joint assembly (11) to remove it.
1
4 Center swivel joint assembly: 70 kg
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
1
fl Regarding the port positioned in the lower
section of the swivel joint, install the swivel
joint so that the “A port” may be directed to
the front-RH side.
• Filling the oil

filler port and circulate the oil inside the pip-
ing. After that, re-check the oil level.
fl Fill the quantity of the oil which leaked when
the swivel joint assembly was removed.
30-106 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
DISASSEMBLY OF CENTER
1
2. Remove snap ring (2). 2
3. Using puller 1, pull out swivel rotor (4) and 3

ring (3) from swivel shaft (5).
4. Remove O-ring (6) and slipper seal (7) from

swivel rotor. 4
CEP00381
ASSEMBLY OF CENTER
1. Assemble slipper seal (7) and O-ring (6) to swivel
rotor.
2. Set swivel shaft (5) on block, then using push

tool 2, tap swivel rotor (4) with a plastic ham-
mer to install.
2 Contact surface of rotor, shaft:
Grease (G2-LI)
fl When installing the rotor, be extremely care-
CEP00382
ful not to damage the slipper seal and O-
ring.
3. Install ring (3) and secure with snap ring (2).
4. Fit O-ring and install cover (1).

3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
PC750, 800-6 30-107

1
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
REMOVAL OF TRAVEL MOTOR

ASSEMBLY
 Swing the work equipment 90˚, then lower it
completely to the ground.
 Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
1. Lift off cover (1).
4 Cover: 120 kg
2. Disconnect hoses (2), (3), (4), and (5). 1

fl Fit blind plugs into the hoses.
3. Remove 2 mounting bolts from travel motor and

set tool K in position.
4. Remove remaining mounting bolts, then pull out

travel motor assembly (6) and sling. 2
5. Lift off travel motor assembly (6). 3
4 Travel motor assembly: 150 kg
INSTALLATION OF TRAVEL
MOTOR ASSEMBLY
removal.
1
fl After connecting the hoses, add engine oil
through plug (7) until it reaches the bottom
of the port.
2
3 Mounting bolt:
384.7 ± 41.65 Nm {39.25 ± 4.25 kgm}
3
fl There is no air bleed plug, so add oil through
the brake valve side plug when installing.
fl Run the engine to circulate the oil through
the system. Then add engine oil to the hy-
draulic tank to the specified level.
30-108 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
DISASSEMBLY OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
1. Remove nut (1), then remove disc (2) and boot
(3).
2. Remove bolt, then remove plate (5).

fl Do not remove joint (4) unless it is to be
replaced.
3. Remove seal (6) and collar (7).
4. Pull out piston (8), and remove retainer (9),

springs (10) and (11), and shim (12).
fl Spring (10) consists of two springs each of two
types with different installed loads, so check the
mounting position (hydraulic port) and mark with
tags to prevent mistakes when installing.
5. Pull out valve (13) from body (14).
PC750, 800-6 30-109

1
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
ASSEMBLY OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) to valve
(13).
fl When assembling spring (11), set the end
with the small coil diameter (inside diam-
eter) at shim (12) end.
3. Assemble spring (10), retainer (9), and piston
(8).
fl The number of loops in the coil for spring
(10) is different for each of the hydraulic
ports below, so be careful when installing.
Positon of port Free length of spring (mm)

P1, P2 38.71
P3, P4 42.48
fl The position of each port is marked at the

bottom of the valve body.
2 Piston: Grease (G2-LI)
fl When assembling piston (8), coat the out-
side circumference of the piston and the in-
side circumference of the hole in the body
with grease.
4. Fit O-ring to collar (7) and assemble to body
(14), then install seal (6).
5. Install plate (5). 5∼7mm
3 Mounting bolt:
13.23 ± 1.47 Nm {1.35 ± 0.15 kgm}
6. Install joint (4).
2 Joint sliding surface: Grease (G2-LI)
2 Female thread in body:
Thread tightener (LT-2)
fl Coat two places on the female thread with
one drop of Loctite each as shown in the
diagram on the right.
3 Joint: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm} CEP00425
fl Keep strictly to the tightening torque for the

joint.
7. Assemble boot (3) and disc (2), and tighten with
nut (1).
3 Nut: 112.7 ± 14.7 Nm {11.5 ± 1.5 kgm}
fl After assembling the disc, adjust the height
of the disc.
Adjusting PPC valve.
30-110 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
DISASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Remove screw (1), then remove lever (2).
2. Remove mounting bolt (3), then remove case

and shaft assembly (4).
3. Remove 4 mounting bolts (5), then remove plate

and damper assembly (6).
fl Check the thickness and mounting position
of washer (7).
4. Remove mounting bolt (8), then remove damper

assembly (8) from plate (10).
5. Remove seal (11) and collar (12).
6. Pull out piston (13), and remove retainer (14),

springs (15) and (16), and shim (17).
fl Check the number and thickness of shims
(17) for each mounting position, and keep in
a safe place.
7. Pull out valve (18) from body (19).
8. Disassembly of case and shaft assembly

1) Knock pin (20) in shaft and remove shaft
(21).
2) Remove lever (22).
3) Pull out pin (20) from shaft (21).
PC750, 800-6 30-111

1
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
ASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Assemble valve (18) to body (19).
2. Assemble shim (17) and spring (16) to valve
(18).
fl Assemble the same number and thickness
of shim (17) in the same position as was
removed during disassembly.
Standard shim thickness : 0.3 mm
fl Spring (16) is not symmetrical at the top
and bottom, so assemble with the small coil
diameter (inside diameter) at the shim end.
3. Assemble spring (15), retainer (14), and piston
(13).
2 Outside circumference of piston, body hole:
Grease (G2- LI)
4. Fit O-ring to collar (12) and assemble to body
(19), then install seal (11).
5. Install damper assembly (9) to plate (10), and
tighten mounting bolt (8).
3 Mounting bolt:
4.41 ± 0.49 Nm {0.45 ± 0.05 kgm}
6. Install plate and damper assembly (6), and
tighten mounting bolt (8).
fl Temporarily assemble standard washer (1.6
mm) for washer (7).
After completing the assembly, measure the
difference in the angle when the left and
right levers are operated fully. If the angle is
greater than 0.7˚, change the thickness of
washer (7) to make the difference less than
0.7˚.
• Washer thickness 1.0, 1.3, 1.6 mm
fl If the washer is made 0.3 mm thinner,
the angle at the full stroke is increased
by 0.39˚.
3 Mounting bolt:
30.87 ± 3.43 Nm {3.15 ± 0.35 kgm}
7. Install case and shaft assembly (4), and tighten
mounting bolt (3).
2 Rocking portion of shaft, connection of
lever and piston: Grease (G2-LI)
3 Mounting bolt:
27.95 ± 3.43 Nm {2.85 ± 0.35 kgm}
8. Install lever (2), and tighten screw (1).
2 Rocking portion of lever pin and plate:
Grease (G2-LI)
3 Screw: 8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}
30-112 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
BACK HOE
 Retract the arm and bucket cylinder piston rods,
lower the work equipment completely to the
ground, then set the safety lock lever to the
LOCK position.
1. Set block 1 between bucket cylinder and arm,

and block 2 between link and arm.
2. Remove 3 pin lock bolts (1) and cover (2), then

using forcing screws, pull out. 1
3. Start engine, and retract piston rod, then tie

piston rod with wire to prevent it from coming
out.
 Stop the engine and release the remaining
pressure in the circuit. For details, see TEST-
ING AND ADJUSTING, Releasing pressure
in hydraulic circuit.
4. Disconnect 2 hoses (3).

fl Fit blind plugs in the hoses to prevent dust
or dirt from entering.
5. Sling bucket cylinder assembly (5), then remove

plate (6) and pull out pin (7). 2
fl There are shims installed, so check the num-
ber, thickness, and position, and keep in a
7 6
safe place. 5
6. Remove bucket cylinder assembly (5).
4 Bucket cylinder assembly:

550 kg (PC750)
980 kg (PC750SE, PC800SE)
600 kg (PC800)
CEP00077
PC750, 800-6 30-113

1
LOADING SHOVEL
 Extend the arm cylinder fully, set the bottom of
the bucket horizontal, lower the work equipment
completely to the ground and stop the engine.
Operate the control levers several times to re-
lease the remaining pressure in the hydraulic
piping.

fl Fit blind plugs in the hoses after disconnecting

them, to prevent dirt or dust from entering.
1. Sling bucket cylinder assembly, and remove 3

mounting bolts, then using forcing screws
(Thread dia. = 16 mm, Pitch = 2.0 mm), remove
pin (1). 1
 When the pin is removed, links (2) and (3)
will drop, so sling the links before removing
the pin.
4 Pin: 37 kg
2. Start engine and retract piston rod fully.

 Tie the rod with wire to prevent it from com-
ing out.
 After stopping the engine, release the pres-
sure inside the piping.
Releasing pressure in PPC circuit.
3. Disconnect grease tube (4).
4. Disconnect hose (5).
5. Sling piston rod end and bottom end, and re-

move plate, then using forcing screws (Thread
dia. = 16 mm, Pitch = 2.0 mm), pull out pin (6).
2
fl Pull out the pin to a position where the cyl-
inder bottom can be disconnected.
4 Pin: 35 kg
6. Raise bucket cylinder assembly (7) carefully and

remove.
4 Bucket cylinder assembly: 555 kg
30-114 PC750, 800-6

1
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY
BACK HOE
removal.
1
2 Inside surface of bushing when assem-
bling pin: Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
 When aligning the position of the pin hole,
never insert your fingers in the hole.
fl Adjust with shims (4) so that the clearance a
between link (7) and cover (2) is less than 1
mm.
• Shim thickness: 0.8 mm (STD)
1.0 mm (SE)
2
Grease (LM-G)
fl Adjust with shims (9) so that the clearance b
between bracket (8) and the end face of of
bottom of cylinder (5) is less than 1 mm.
• Shim thickness: 0.8 mm (STD)
1.0 mm (SE)
• Bleeding air
fl Bleed the air.
Bleeding air.
• Refilling with oil (hydraulic tank)

fl Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
PC750, 800-6 30-115

1
LOADING SHOVEL
removal.
1
 When aligning the mounting position of the
pin, do not insert your fingers in the pin
hole.
2
hole.
fl Adjust with shims so that the clearance
at the cylinder bottom end is less than 1
mm.
fl Bleed the air from the work equipment circuit.

Bleeding air from hydraulic cylinder.
• Refilling with oil

fl Add oil to the specified level, and run the
engine to circulate the oil through the sys-
tem. Then check the oil level again.
30-116 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
REMOVAL OF ARM CYLINDER

ASSEMBLY
4
BACK HOE
 Extend the arm cylinder piston rod to a point
approx. 200 mm before the end of the IN stroke,
lower the work equipment completely to the
ground, then set the safety lock lever to the 1
LOCK position. 2
3
1. Set block 1 between arm cylinder and boom.
2. Disconnect grease hose (1).

CEP00522
3. Remove plate (3), and pull out head pin (3).
1
fl If the pin does not come out, use tool V2
and remove the pin from the head end.

out.
5. Disconnect hose (4) and grease hose (5).

fl Fit blind plugs in the hoses to prevent dust
or dirt from entering. 8 7 5
6. Sling arm cylinder assembly (6), then remove

plate (7) and pull out bottom pin (8). 2
and remove the pin from the bottom end.
ber, thickness, and position, and keep in a 6
safe place.
CEP00523
7. Remove arm cylinder assembly (6). 2
4 Arm cylinder assembly:

915 kg (PC750STD)
540 kg × 2 (PC750SE, PC800, PC800SE)
PC750, 800-6 30-117

1
LOADING SHOVEL
 Retract boom cylinder fully, and extend arm cyl-
inder, then set the bottom of the bucket hori-
zontal, lower the work equipment completely to
the ground and stop the engine. Operate the
control levers several times to release the re-
maining pressure in the hydraulic piping.


1. Disconnect grease tube (1) at piston rod end.
2. Sling arm cylinder assembly, and remove plate,

then using forcing screws (Thread dia. = 16 mm,
Pitch = 2.0 mm), pull out pin (2). 1
fl Pull out the pin to a position where the pis-
ton rob can be disconnected.
4 Pin: 56 kg

ing out.
4. Disconnect hose (3).
5. Sling piston rod end and bottom end, and re-

move plate, then using forcing screws (Thread
dia. = 16 mm, Pitch = 2.0 mm), pull out pin (4).
2
fl Pull out the pin to a position where the cyl-
inder bottom can be disconnected.
4 Pin: 56 kg
6. Lift off arm cylinder assembly (5) carefully.
4 Arm cylinder assembly: 845 kg
30-118 PC750, 800-6

1
INSTALLATION OF ARM
CYLINDER ASSEMBLY
BACK HOE
removal.
1
Grease (LM-G)
1
Grease (LM-G)
fl Adjust with shims (10) so that the clearance
a between bracket (9) and the bottom end
face of cylinder (6) is less than 1 mm.
• Shim thickness: 0.8 mm
• Bleeding air
fl Bleed the air.
Bleeding air.

PC750, 800-6 30-119

1
LOADING SHOVEL
removal.
 When aligning the mounting position of the pin,

do not insert your fingers in the pin hole.
 When aligning the mounting position of the pin,

do not insert your fingers in the pin hole.
fl Adjust with shims so that the clearance at
the cylinder bottom end is less than 1 mm.


30-120 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM
CYLINDER ASSEMBLY
BACK HOE
 Retract the arm and bucket cylinder piston rods
fully, lower the work equipment completely to
the ground, then put the safety lock lever in the
LOCK position.
fl Fit blind plugs in the hoses to prevent dust or
dirt from entering.
1. Disconnect grease tube (1).
2. Remove plate (2).
3. Sling boom cylinder assembly.
4. Using tool V3, pull out head pin (3), then dis-
connect piston rod from boom. 1

out.
6. Lower boom cylinder assembly on stand, then

disconnect hose (4).
8. Sling boom cylinder assembly and remove plate

(6).
9. Using tool V1, pull out bottom pin (7). 2
10. Remove boom cylinder assembly.
4 Boom cylinder assembly: 840 kg × 2
PC750, 800-6 30-121

1
LOADING SHOVEL
 Extend the arm and bucket fully, lower the work
equipment completely to the ground and stop
the engine. Operate the control levers several
times to release the remaining pressure in the
hydraulic piping.


2. Remove plate (2).
3. Sling boom cylinder assembly, then using forc-

ing screws (Thread dia. = 16 mm, Pitch = 2.0
mm), pull out pin (3), and disconnect piston rod
from boom. 1

ing out.
5. Lower boom cylinder assembly onto stand, then

disconnect hose (4).
6. Sling boom cylinder assembly, and remove plate,

then using forcing screws (Thread dia. = 16 mm,
Pitch = 2.0 mm), pull out foot pin (5). 2
7. Remove boom cylinder assembly (6).
4 Boom cylinder assembly: 720 kg
30-122 PC750, 800-6

1
CYLINDER ASSEMBLY
BACK HOE
removal.
1
Grease (LM-G)
2
Grease (LM-G)
fl Adjust with shims (10) so that the clearance
a between bracket (9) and the bottom end
face of boom cylinder (8) is less than 1 mm.
• Shim thickness: 1.0, 1.5 mm
• Bleeding air
fl Bleed the air.
Bleeding air.

PC750, 800-6 30-123

1
LOADING SHOVEL
removal.
1
hole.
2
hole.
fl Adjust with shims so that the clearance
at the cylinder bottom end is less than 1
mm.


30-124 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY BOTTOM DUMP CYLINDER
REMOVAL OF BOTTOM DUMP

CYLINDER ASSEMBLY
LOADING SHOVEL
 Set the bottom of the bucket horizontal, and
retract the rod to a position where the rod con-
necting pin of the bottom dump cylinder can be
removed. Then fit a block under the bucket, lower
the work equipment completely to the ground
and stop the engine.

2. Sling bottom dump cylinder assembly, and re-

move lock plate, then using forcing screws
(Thread dia. = 16 mm, Pitch = 2.0 mm), pull out
pin (2). 1

4. Remove hose (3).
5. Remove 3 mounting bolts, then using forcing

screws (Thread dia. = 16 mm, Pitch = 2.0 mm),
pull out pin (4). 2
4 Pin: 35 kg
6. Lift off bottom dump cylinder assembly (5).
4 Bottom dump cylinder assembly: 140 kg
PC750, 800-6 30-125

1
DISASSEMBLY AND ASSEMBLY BOTTOM DUMP CYLINDER
INSTALLATION OF BOTTOM
DUMP CYLINDER ASSEMBLY
LOADING SHOVEL
removal.
1
hole.
2
hole.


30-126 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Piston rod assembly 1
1) Secure bottom end of cylinder assembly (1)
with tool U1 or press, then remove mount- 2
ing bolts, and disconnect head assembly (2). 3
Bolt width across flats Unit : mm

Cylinder Boom Arm Bucket Bottom
dump
PC750
41 46 36 —
PC750LC CEP00001
PC800 STD 41 36 36 —
PC750SE 41 36 46 —
PC800SE 41 36 46 —
PC750 1 3
41 46 36 27
Loading shovel
3
U1
2) Pull out piston rod assembly (3).
fl Place a container under the cylinder to
catch the oil.
2. Piston assembly, head assembly

1) Secure head end of piston rod assembly (3) CEP00002
with tool U1 or press.
2) Remove screw (4), and remove 11 balls (5),

8 7
then remove plunger (6). 11
fl Arm cylinder only 4
3) Remove 6 screws (7), then remove spacer 5
(8).
4) Remove piston assembly (9), O-ring, and
backup ring (10).
5) Remove plunger (11).
6
9 10 CEP00003
PC750, 800-6 30-127

1
6) Disassembly of piston assembly

9
i) Remove ring (12).
ii) Remove wear ring (13). 12
iii) Remove piston ring (14). 13
14
13
12
CEP00004
7) Remove collar assembly (15) and head as-

sembly (2) from piston rod (3). 15 2 3
CEP00005
8) Disassembly of collar
i) Remove O-ring and backup ring (16).
ii) Remove rings (18) and (19) from collar
(17).
9) Disassembly of head assembly

i) Remove O-ring and backup ring (20).
25
ii) Remove snap ring (21), then remove dust 20
seal (22).
iii) Remove rod packing (23).
iv) Remove buffer ring (24). 24
v) Remove bushing (25).
22
23
21
CEP00006
30-128 PC750, 800-6

1
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
U4 25
fl Be careful not to damage the packings, dust 20
seals, and O-rings. 25
24
fl Do not try to force the backup ring into position.
Warm it in warm water (50 – 60˚C) before fitting
it.
1. Assembly of head assembly

1) Using tool U4, press fit bushing (25).
23
2) Assemble buffer ring (24).
21 22
3) Assemble rod packing (23). CEP00283 CEP00284
4) Using tool U5, assemble dust seal (22), and

secure with snap ring (21).
5) Assemble O-ring and backup ring (20).
2. Assembly of collar assembly U5

1) Assemble rings (19) and (18) to collar (17). 22
2) Assemble O-ring and backup ring (16).
CEP00298
3. Assembly of piston assembly

1) Using tool U2, expand piston ring (14).
U3
fl Set the piston ring on tool U2 and turn
the handle 8 – 10 times to expand the U2
14
ring.
2) Assemble piston ring (14) to piston. 14
3) Set tool U3 in position and retract piston
ring (14).
4) Assemble wear ring (13).
5) Assemble ring (12).
fl Be careful not to open the end gap of
the ring too wide. CEP00008 CEP00009
2 Ring groove: Grease (G2-LI)
9
12
13
14
13
12
CEP00004
PC750, 800-6 30-129

1
4. Piston rod assembly

1) Secure head end of piston rod to tool U1 or 15
press.
2) Assemble head assembly (2) and collar (15)
to rod.
3) Install plunger (11), O-ring, and backup ring
(10).
4) Install piston assembly (9) and spacer (8),
and tighten with screw (7).
fl Wash the bolt thread thoroughly and re-
move all oil and grease, then coat with a 2
hardening accelerator. CEP00010
2 Bolt:
Thread tightener (Loctite No. 262)
3 Bolt:
Bolt diameter Tightening torque
110.25 ± 12.25 Nm
12 mm
{11.25 ± 1.25 kgm}
176.4 ± 19.6 Nm
14 mm
{18 ± 2 kgm}
276.85 ± 31.85 Nm
16 mm
{28.25 ± 3.25 kgm}
5) Set plunger (6) to piston rod, then assemble

ball (5), and tighten screw (4).
fl Ball: 11 (for STD)
10 (for SE and Loading shovel)
8 7
Check the number of balls when as- 11
sembling. 4
fl Wash the bolt thread thoroughly and re- 5
move all oil and grease, then coat with a
hardening accelerator.
2 Screw (4):
Thread tightener (Loctite No. 262)
3 Screw (4)
6
Model Tightening torque
STD, 308.7 ± 34.3 Nm 9 10 CEP00003
Loading shovel {31.5 ± 3.5 kgm}
156.8 ± 19.6 Nm
SE
{16 ± 2 kgm}
6) After tightening screw, check that there is

play in plunger, then caulk screw (4).
(arm cylinder only)
30-130 PC750, 800-6

1
5. Cylinder assembly
1) Secure cylinder tube bottom end with tool
U1 or press. 3
1
2) Assemble piston rod assembly (2).
2 Seal portion: Grease (G2-LI)
fl Set the end gap of the ring at the hori- 3
U1
zontal (side) position, align the center of
shaft and cylinder tube, then insert.
fl After inserting, check that the ring is not
broken and has not come out, then push
in fully.
3) Tighten head assembly (1) with mounting CEP00002
bolts.
3 Mounting bolt:
Bolt width across flats Tightening torque

1
373 ± 54 Nm
27 mm
{38 ± 5.5 kgm} 2
892 ± 137 Nm 3
36 mm
{91 ± 14 kgm}
1.27 ± 0.2 Nm
41 mm
{130 ± 20 kgm}
1.67 ± 0.25 Nm
46 mm
{170 ± 25 kgm} CEP00001
PC750, 800-6 30-131

1
DISASSEMBLY AND ASSEMBLY BUCKET
REMOVAL OF BUCKET
ASSEMBLY
BACK HOE
 Set the back of the bucket facing down, lower
the work equipment completely to the ground,
then set the safety lock lever to the LOCK posi-
tion.
1. Remove 3 pin lock bolts (1), then remove stop-

per (2).
2. Using forcing screws, remove connecting pin of

link and bucket. 1
3. Start engine, and retract piston rod, then tie link

to arm with wire to prevent piston rod from
coming out.
4. Remove 3 pin lock bolts (3), then remove stop-

per (4).
5. Remove cover (5), then remove shims (6).

6. Using forcing screws, remove arm connecting

pin (7). 2
7. Start engine and raise work equipment, discon-

nect arm from bucket, then remove bucket as-
sembly.
4 Bucket assembly: 2,960 kg (PC750STD)

3,560 kg (PC800STD)
3,435 kg (PC750SE)
3,870 kg (PC800SE)
30-132 PC750, 800-6

1
LOADING SHOVEL
 Set the bottom of the bucket horizontal, lower
the work equipment completely to the ground
and stop the engine. Operate the control levers
several times to release the remaining pressure
in the hydraulic piping.


1. Disconnect bottom dump cylinder hose (1).
2. Sling bucket cylinder assembly, and remove 3

mounting bolts, then using forcing screws
(Thread dia. = 16 mm, Pitch = 2.0 mm), pull out
pin (2).
fl Remove the pin on the other side in the
same way. 1
 When the pin is removed, link (3) will drop,
so sling the links before removing the pin.
4 Pin: 37 kg
4 Link: 440 kg
3. Sling bucket assembly, and remove 3 mounting

bolts, then using forcing screws (Thread dia. =
16 mm, Pitch = 2.0 mm), pull out pin (4). 2
same way.
4 Pin: 52 kg
4. Lift off bucket assembly (5).
4 Bucket assembly: 5,700 kg
PC750, 800-6 30-133

1
INSTALLATION OF BUCKET
ASSEMBLY
BACK HOE
removal.
1
Grease (LM-G)
2
Grease (LM-G)
fl Insert the O-ring at the end face of the bucket
boss securely.
fl Adjusting of bucket clearance
1) Measure clearance a between arm (8)
and bushing (9).
fl It is easier to measure if the bucket
is moved to one side so that all the
play is in one place.
2) Select shims so that clearance a is 0.5 –
1.0 mm.
• Shim thickness b: 0.5, 1.0 mm
3) Install selected shims and install cover
(5).
30-134 PC750, 800-6

1
LOADING SHOVEL
removal.
12

hole.

After completion of the air bleeding operation,
add engine oil to the hydraulic tank to the speci-
fied level.
PC750, 800-6 30-135

1
DISASSEMBLY AND ASSEMBLY ARM
REMOVAL OF ARM ASSEMBLY

BACK HOE
1. Remove bucket assembly.
For detail, see REMOVAL OF BUCKET ASSEM-
BLY. 5
6
2
2. Secure link to arm with wire. 3
 Extend the arm cylinder piston rod to a point 4
approx. 200 mm before the end of the IN
stroke, then lower the arm on to block 1
and stand 2, and set the safety lock lever to 1
the LOCK position. Then, stop the engine.
CEP00525
3. Set block between arm cylinder and boom.
5. Remove plate (2), and pull out head pin (3) of

arm cylinder. 1
and remove the pin from the head end.

out.
7. Disconnect 2 bucket cylinder hoses (4).
8. Remove plate (5), then using tool V3, pull out

boom top pin (6). 2
safe place.
9. Start engine, then raise boom and remove arm

assembly (7).
4 Arm assembly:
3,960 kg (PC750STD) 7
4,530 kg (PC800STD)
4,930 kg (PC750SE, PC800SE)
CEP00526
30-136 PC750, 800-6

1
LOADING SHOVEL
1. Remove bucket assembly.

For details, see REMOVAL OF BUCKET ASSEM-
BLY.
2. Start engine, and set work equipment so that

bucket cylinder is perpendicular.
3. Remove 3 mounting bolts, then using forcing

screws (Thread dia. = 16 mm, Pitch = 2.0 mm),
pull out pin (1). 1
same way, then secure the link to the arm
with wire so that it cannot move.
4. Disconnect left and right bottom dump cylinder

hoses (2).
5. Remove cover (3), and disconnect wiring (4) of

potentiometer.
6. Remove 3 mounting bolts (5), then remove po-

tentiometer (6) together with bracket (7).
7. Remove arm cylinder from arm.

For details, see REMOVAL OF ARM CYLINDER
ASSEMBLY.
fl Secure the arm cylinder assembly to the
boom with lever block 1.
8. Sling arm assembly, and remove 3 mounting

bolts, then using forcing screws (Thread dia. =
16 mm, Pitch = 2.0 mm), pull out pin (8). 2
fl Pull out the pin on the other side in the
same way to a position where the arm can
be disconnected from the boom.
4 Pin: 45 kg
9. Lift off arm assembly (9).
4 Arm assembly: 3,070 kg
PC750, 800-6 30-137

1
INSTALLATION OF ARM
ASSEMBLY
BACK HOE
removal.
1
Grease (LM-G)
1
Grease (LM-G)
fl Adjust with shims so that the clearance a
between boom (8) and the bottom end face
of arm (7) is less than 1 mm.
• Shim thickness : 1.0 mm
• Bleeding air
fl Bleed the air.
Bleeding air.

30-138 PC750, 800-6

1
LOADING SHOVEL
removal.
12
hole.

fied level.
PC750, 800-6 30-139

1
DISASSEMBLY AND ASSEMBLY BOOM
REMOVAL OF BOOM
ASSEMBLY
BACK HOE
1. Remove bucket and arm assembly.
For details, see REMOVAL OF BUCKET, ARM
ASSEMBLY.
 Lower the boom assembly completely to the
ground, then set the safety lock lever to LOCK
position.
2. Disconnect boom cylinder assembly from boom.

For details, see REMOVAL OF BOOM CYLINDER
ASSEMBLY.
3. Disconnect front lamp wiring.
4. Disconnect bucket cylinder hoses (1) and arm

cylinder hoses (2).
5. Sling boom assembly (10).
6. Using tool V1, remove 2 boom foot pins (7),

then remove boom assembly. 1
safe place. 10
CEP00299
4 Boom assembly: 8,360 kg (PC750STD)
8,790 kg (PC800STD)
7,970 kg (PC750SE,
PC800SE)
30-140 PC750, 800-6

1
LOADING SHOVEL
1. Remove arm assembly.

For details, see REMOVAL OF ARM ASSEMBLY.
2. Sling bucket cylinder assembly (1), remove plate,

then pull out pin (2), and remove bucket cylin-
der assembly. 1
4 Pin: 35 kg
4 Bucket cylinder assembly: 555 kg
fl Remove the bucket cylinder on the other

side in the same way.
3. Sling boom, set stand 1 at tip of boom to sup-

port boom.
4. Remove boom cylinder from boom.

ASSEMBLY.
fl Remove the boom cylinder on the other side
from the boom in the same way.
5. Disconnect bottom dump cylinder hose (3),

bucket cylinder hose (4), and arm cylinder hose
(5).
fl When the hoses are disconnected, oil may
spurt out, so loosen the hose flanges slowly
before disconnecting.
6. Disconnect head lamp wiring.
7. Remove cover (6), and disconnect wiring (7) of

potentiometer and cable (8).
PC750, 800-6 30-141

1
ASSEMBLY
BACK HOE
removal.
1
Grease (LM-G)
fl Adjust with shims so that the clearance a
between bracket (4) and the end face of the
foot of boom (3) is less than 1 mm.
• Shim thickness : 1.0, 1.5 mm
• Bleeding air
fl Bleed the air.
Bleeding air.

30-142 PC750, 800-6

1
8. Remove 3 mounting bolts (9), then remove po-

tentiometer assembly (10) together with bracket
(11).
9. Using forcing screws (Thread dia. = 16 mm, Pitch

= 2.0 mm), pull out left and right boom foot pins
(12), then lift off boom (13). 2
4 Boom: 4,490 kg
LOADING SHOVEL
removal.
12

hole.

fied level.
PC750, 800-6 30-143

1
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT
BACK-HOE
 Contract the arm and bucket cylinder piston rods,
lower the work equipment to touch the ground
completely and set the safety lock lever to the
lock position.
fl Referring to the section “Releasing the remain-
ing pressure from the hydraulic circuit” in the
“Testing and adjusting”, release the remaining
1. Referring to the section “Removal of the boom

cylinder assembly”, separate the boom cylinder
assembly from the boom.
2. Separate the head lamp wire.
3. Separate the bucket cylinder hose (1) and the

arm cylinder hose (2).
4. Temporarily hang the work equipment assem-

bly.
5. Using the tool V1, remove the 2 pcs. of the

boom foot pin (7). 1
fl Since the shim is being installed, confirm
the number of sheets and the position.
6. Start the engine, back the machine slowly and

lower the boom foot section to touch the ground
using a crane.
 When backing the machine, confirm that the
boom foot section is completely separated
from the machine body side before starting
backing of the machine.
4 Work equipment assembly:

15,300 kg (PC750STD)
16,900 kg (PC800STD)
16,300 kg (PC750SE)
16,700 kg (PC800SE)
30-144 PC750, 800-6

1
LOADING SHOVEL
 Retract the boom cylinder fully, extend the arm
cylinder, set the bottom of the bucket horizon-
tal, then lower the work equipment completely
to the ground and stop the engine. Operate the
control levers several times to release the re-
maining pressure in the hydraulic piping. Then
loosen the oil filler cap slowly to release the
fl Release the remaining pressure in the circuit.
For details, see TESTING AND ADJUSTING, Re-
leasing pressure in hydraulic circuit.
1. Disconnect boom cylinder from boom.

ASSEMBLY.
2. Disconnect bottom dump cylinder hose (1),

bucket cylinder hose (2), and arm cylinder hose
(3).
fl When the hoses are disconnected, oil may
spurt out, so loosen the hose flanges slowly
before disconnecting.
 To prevent oil from spurting out when the
engine is started, fit blind plugs securely in
the piping at the chassis end.
3. Disconnect head lamp wiring.
4. Remove potentiometer assembly.

For details, see REMOVAL OF BOOM ASSEM-
BLY.
5. Set bottom of bucket horizontal, lower work

equipmemt completely to ground, then sling
boom assembly (4).
6. Using forcing screws (Thread dia. = 16 mm, Pitch

= 2.0 mm), pull out left and right boom foot pins
(5), then disconnect work equipment assembly
(4).
7. Start engine, drive machine slowly in reverse,

and operate crane to lower boom foot to ground.
 Before driving the machine in reverse, check
that the boom foot is completely separated
from the machine body.
4 Work equipment assembly: 16,200 kg
PC750, 800-6 30-145

1
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
BACK-HOE
1
2 To the inner surface of the bushing when
assembling the pin:
Anti-friction material (LM-P)
2 Greasing after assembling the pin:
Grease (LM-G)
 When matching the position of the pin hole,
never insert finger into the pin hole.
fl Make adjustment so that the clearance a be-
tween the end face of the foot of the boom
(3) and the bracket (4) may become 1 mm or
less, using the shim (5).
• Shim thickness: 1.0 and 1.5 mm
• Air bleeding
fl Carry out air bleeding referring to the section
“Air bleeding of each section” in the “Test-
ing and adjusting”.

the oil level.
30-146 PC750, 800-6

1
LOADING SHOVEL
removal.
1
hole.
fl Adjusting the lifting height of the boom as-
sembly so that the boom foot is at the height
of the mount on the chassis.

fied level.
PC750, 800-6 30-147

1
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
REMOVAL OF OPERATOR’S
CAB ASSEMBLY
 Disconnect the cable from the negative (–) ter-
minal of the battery.
1
1. Remove floor mat.
2. Remove operator’s seat (1).

fl Be careful not to damage the cover.
CEP00438
3. Remove knob (2).

3
4. Remove 4 bolts and 1 clip, then remove panels
(3) and (4).
2
4 CEP00439
5. Disconnect hose (5) for window washer.

6 7
6. Remove plate (6), then remove left cover (7).
5
CEP00440 CEP00441
7. Disconnect hose (8) and speaker wiring connec-

tor, and remove right cover (9).
fl Lift up right cover (9) slightly before discon-
necting the speaker wiring connector.
CEP00442
30-148 PC750, 800-6

1
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
8. Remove the cover (10) and duct (11).
9. Separate the air conditioner cable (12). 11
10. Separate the 15 pcs. of the connectors (14).

fl Panel side : CN-X07 (MIC17)
fl Pump controller : CN-C01 (MIC13)
: CN-C02 (MIC21)
: CN-C03 (AMP040-20)
: CN-C16 (MIC17) 10
fl Intermediate section of the harness
: CN-H12 (S16) White CEP00443
: CN-H13 (S16) Blue

: CN-H14 (M8)
: CN-H15 (L2)
: CN-M94 (M4)
: CN-M72 (X3)
: CN-L03 (M2)
fl Speaker : CN-M13 (KES-2)
fl For the air conditioner
: CN-AC1 (AMP040-20)
: CN-AC2 (AMP040-12)
11. Remove the 4 pcs. of the mounting nuts and the

6 pcs. of the mounting bolts and hang the
operator’s cab assembly to remove the
operator’s cab. 1
4 Operator’s cab: 300 kg (PC750)

350 kg (PC800)
• The ª mark shows the nut and the ▲ mark
shows the bolt. ※ ※
fl Regarding the bolt, confirm the length in
advance.
※ ※
CEP00445
INSTALLATION OF 15
OPERATOR’S CAB ASSEMBLY
1
3 Mounting nut:
276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
CEP00446
PC750, 800-6 30-149

1
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF
COUNTERWEIGHT ASSEMBLY
1. Set chain to lifting hook of counterweight as-
sembly, and sling.
2. Remove mounting bolts (1).
3. Lift off counterweight assembly (2). 1
4 Counterweight assembly:
12,000 kg (PC800)
9,800 kg (PC750)
INSTALLATION OF
COUNTERWEIGHT ASSEMBLY
removal.
1
fl Adjust the stepped difference (top and bot-
tom clearance) from the bodywork with
shims.
fl Install so that the clearance between the
counterweight and the revolving frame is 15
mm, and so that the stepped difference is
uniform on the left and right.
3 Counterweight mounting bolt:
3,822 ± 392 Nm {390 ± 40 kgm}
30-150 PC750, 800-6

1
90 OTHERS
Hydraulic circuit drawing .......................................................................... 90- 3

Electric circuit diagram (1/4) ..................................................................... 90- 5
Electric circuit diagram (4/4) ..................................................................... 90-11
PC750, 800-6 90-1

OTHERS HYDRAULIC CIRCUIT DRAWING
HYDRAULIC CIRCUIT DRAWING
PC750, 800-6 90-3

OTHERS ELECTRIC CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM (1/4)
PC750, 800-6 90-5

PC750, 800-6 90-7

PC750, 800-6 90-9

PC750, 800-6 90-11

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SEBM025303

MACHINE MODEL SERIAL NUMBER

PC750-6 11001 and up

• PC750, 800-6 mount the SAA6D140E-3 engine.

01 GENERAL ........................................................................ 01-1

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD .... 10-1

20 TESTING AND ADJUSTING .......................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ................................. 30-1

00-2 PC750, 800-6

The affected pages are indicated by the use of the

‡ Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGE

Time of Time of Time of Time of Time of

‡ 00- 1 (3) 01- 1 10-10 10-39 10-70

PC750, 800-6 00-2-1

Time of Time of Time of Time of Time of

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

00-2-2 PC750, 800-6

Time of Time of Time of Time of Time of

20-151 20-264 20-401 20-442 20-564

PC750, 800-6 00-2-3

Time of Time of Time of Time of Time of

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

00-2-4 PC750, 800-6

IMPORTANT SAFETY NOTICE

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

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

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

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,