PC750-7 Shop Manual PDF

SEBM031303
MACHINE MODEL SERIAL No.

PC750-7 20001 and up
PC750SE-7 20001 and up
PC750LC-7 20001 and up
PC800-7 40001 and up
PC800SE-7 40001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
• PC750, 800-7 mounts the SAA6D140E-3 engine.

For details of the engine, see the 6D140-3 Series Engine Shop Manual.
© 2004
All Rights Reserved
Printed in Japan 09-04 (01)
00-1
(3)
GENERAL
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD............................................ 10-1
20 TESTING AND ADJUSTING ........................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
90 OTHERS ................................................................................................................................ 90-1
00-2 PC750, 800-7

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LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. 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.
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 10-37 10-68

00-2 (2) 01-2 (3) 10-11 10-38 10-70
00-2-1 (3) 01-3 10-11-1 (3) 10-39 10-71
00-2-2 (3) 01-3-1 (3) 10-11-2 (3) 10-40 10-72
00-2-3 (3) 01-3-2 (3) 10-12 10-42 10-73
00-2-4 (3) 01-4 (3) 10-13 10-43 10-74
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00-4 01-7 10-16 10-46 10-77
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00-6 01-9 10-18 10-48 10-79
00-7 01-9-1 (3) 10-19 (1) 10-49 10-80
00-8 01-9-2 (3) 10-20 10-50 10-81
00-9 01-10 10-21 10-51 10-82
00-10 01-11 10-22 10-52 10-83
00-11 01-12 10-23 10-53 10-84
00-12 01-13 10-24 10-54 10-85
00-13 01-14 (1) 10-26 10-55 10-86
00-14 10-27 10-56 10-87
00-15 10-28 10-57 10-88
00-16 10-1 (3) 10-29 10-58 10-89
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00-20 10-5 10-33 10-64 10-93
00-21 10-6 10-34 10-65 10-94
00-22 10-7 10-35 10-66 10-96
10-8 10-36 10-67 10-97
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10-113-1 (3) 10-150 20-140 (1) 20-180 (1)
10-113-2 (3) 10-151 20-101 (1) 20-141 (1) 20-181 (1)
10-114 10-152 20-102 (1) 20-142 (1) 20-182 (1)
10-115 10-153 20-103 (1) 20-143 (1) 20-183 (3)
10-116 10-154 20-104 (1) 20-144 (1) 20-184 (1)
10-117 10-155 20-105 (1) 20-145 (1) 20-185 (1)
10-117-1 (3) 10-156 20-106 (1) 20-146 (1) 20-186 (1)
10-117-2 (3) 10-157 20-107 (1) 20-147 (1) 20-187 (1)
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10-125 10-165 20-115 (1) 20-155 (1) 20-196 (1)
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10-127 10-167 20-117 (1) 20-157 (1) 20-201 (1)
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10-129 10-169 20-119 (1) 20-159 (2) 20-203 (1)
10-130 10-170 (3) 20-120 (1) 20-160 (1) 20-204 (1)
10-131 10-171 20-121 (1) 20-161 (1) 20-205 (1)
10-132 10-172 (3) 20-122 (1) 20-162 (1) 20-206 (1)
10-133 10-173 20-123 (1) 20-163 (1) 20-207 (1)
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20-224 (1) 20-307 (1) 20-347 (1) 20-388 (1) 20-429 (1)
20-225 (1) 20-308 (1) 20-348 (1) 20-389 (1) 20-430 (1)
20-226 (1) 20-309 (1) 20-349 (1) 20-390 (1) 20-431 (1)
20-227 (1) 20-310 (1) 20-350 (1) 20-391 (1) 20-432 (1)
20-228 (1) 20-311 (1) 20-351 (1) 20-392 (1) 20-433 (1)
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20-230 (1) 20-313 (1) 20-353 (1) 20-394 (1) 20-435 (1)
20-231 (1) 20-314 (1) 20-354 (1) 20-395 (1) 20-436 (1)
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20-237 (1) 20-320 (1) 20-360 (1) 20-401 (1) 20-442 (1)
20-238 (1) 20-321 (1) 20-361 (1) 20-402 (1) 20-443 (1)
20-239 (1) 20-322 (1) 20-362 (1) 20-403 (1) 20-444 (1)
20-240 (1) 20-323 (1) 20-363 (1) 20-404 (1) 20-445 (1)
20-241 (1) 20-324 (1) 20-364 (1) 20-405 (1) 20-446 (1)
20-242 (1) 20-325 (1) 20-365 (1) 20-406 (1) 20-447 (1)
20-243 (1) 20-326 (1) 20-366 (1) 20-408 (1) 20-448 (1)
20-244 (1) 20-327 (1) 20-367 (1) 20-409 (1) 20-449 (1)
20-245 (1) 20-328 (1) 20-368 (1) 20-410 (1) 20-450 (1)
20-246 (1) 20-329 (1) 20-369 (1) 20-411 (1)
20-247 (1) 20-330 (1) 20-370 (1) 20-412 (1)
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20-509 (1) 20-552 (1) 20-629 (1) 30-9 (2) 30-49 (2)
20-510 (1) 20-553 (1) 20-630 (1) 30-10 (2) 30-50 (2)
20-511 (1) 20-554 (1) 20-631 (1) 30-11 (2) 30-51 (2)
20-512 (1) 20-555 (1) 20-632 (1) 30-12 (2) 30-52 (2)
20-513 (1) 20-556 (1) 20-633 (1) 30-13 (2) 30-53 (2)
20-514 (1) 20-557 (1) 20-634 (1) 30-14 (2) 30-54 (2)
20-515 (1) 20-558 (1) 20-635 (1) 30-15 (2) 30-55 (2)
20-516 (1) 20-560 (1) 30-16 (2) 30-56 (2)
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20-529 (1) 20-608 (1) 20-712 (1) 30-28 (2) 30-68 (2)
20-530 (1) 20-609 (1) 20-713 (1) 30-29 (2) 30-69 (2)
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20-540 (1) 20-618 (1) 20-722 (1) 30-38 (2) 30-78 (2)
20-541 (1) 20-619 (1) 20-723 (1) 30-39 (2) 30-79 (2)
20-542 (1) 20-620 (1) 30-40 (2) 30-80 (2)
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30-81 (2) 30-121 (2) 90-13 (3)
30-82 (2) 30-122 (2) 90-15 (3)
30-83 (2) 30-123 (2) 90-17 (3)
30-84 (2) 30-124 (2)
30-85 (2) 30-125 (2)
30-86 (2) 30-126 (2)
30-87 (2) 30-127 (2)
30-88 (2) 30-128 (2)
30-89 (2) 30-129 (2)
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30-91 (2) 30-131 (2)
30-92 (2) 30-132 (2)
30-93 (2) 30-133 (2)
30-94 (2) 30-134 (2)
30-95 (2) 30-135 (2)
30-96 (2) 30-136 (2)
30-97 (2) 30-137 (2)
30-98 (2) 30-138 (2)
30-99 (2) 30-139 (2)
30-100 (2) 30-140 (2)
30-101 (2) 30-141 (2)
30-102 (2) 30-142 (2)
30-103 (2) 30-143 (2)
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30-109 (2) 30-149 (2)
30-110 (2) 30-150 (2)
30-111 (2) 30-151 (2)
30-112 (2) 30-152 (2)
30-113 (2)
30-114 (2)
30-115 (2) 90-1 (3)
30-116 (2) 90-3 (3)
30-117 (2) 90-5 (3)
30-118 (2) 90-7 (3)
30-119 (2) 90-9 (3)
30-120 (2) 90-11 (3)
PC750, 800-7 00-2-5

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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any 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
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) 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
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
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.
k
Special safety precautions
Safety 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. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
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
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
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 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 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.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(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.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
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
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
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
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
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, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz • Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
• 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 metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite 79A-129-9110 50 cc Polyethylene • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can • Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil an, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
• Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B • Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, 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, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion

SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
• Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district
body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
• "S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material • Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
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.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
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 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 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}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
02 19 34 - 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) (mm2)
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- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — 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.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from 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.
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 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
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, 800-7 01-1

GENERAL SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS
BACKHOE SPECIFICATION
DIMENSIONS
WORKING RANGES
01-2 PC750, 800-7

(3)
DIMENSIONS
Item Unit PC750-7 PC750SE-7 PC750LC-7 PC800-7 PC800SE-7
A Overall length mm 14,305 13,030 14,305 13,895 13,030

B Overall height mm 4,660 4,615 4,660 4,850 4,615
C Overall width mm 4,210 4,210 4,310 4,210 4,210
D Track shoe width mm 710 710 810 710 710
E Height of machine cab mm 3,560 3,560 3,560 3,640 3,640
F Tail swing radius mm 4,300 4,300 4,300 4,300 4,300
G Track overall length mm 5,810 5,810 6,330 5,810 5,810
H Length of track on ground mm 4,500 4,500 5,020 4,500 4,500
Min. ground clearance mm 840 840 840 840 840
WORKING RANGES
Working range Unit PC750-7 PC750SE-7 PC750LC-7 PC800-7 PC800SE-7
A Max. digging reach mm 13,740 12,265 13,740 13,660 12,265

B Max. digging depth mm 8,600 7,130 8,600 8,445 7,130
C Max. digging height mm 11,840 11,330 11,840 11,955 11,330
D Max. vertical wall depth mm 5,575 4,080 5,575 5,230 4,080
E Max. dumping height mm 8,145 7,525 8,145 8,235 7,525
Max. reach at ground
F mm 13,460 11,945 13,460 13,400 11,945
level
PC750, 800-7 01-3

LOADING SHOVEL SPECIFICATION

DIMENSIONS
WORKING RANGES
01-3-1 PC750, 800-7

(3)
DIMENSIONS
Item Unit PC750-7 (Loading shovel specification)
A Overall length mm 9,865

B Overall height mm 5,640
C Overall width mm 4,110
D Track shoe width mm 610
E Height of machine cab mm 3,560
F Tail swing radius mm 4,245
G Track overall length mm 5,810
H Length of track on ground mm 4,500
– Min. ground clearance mm 840
WORKING RANGES
Working range Unit PC750-7 (Loading shovel specification)
A Max. digging reach mm 10,305

B Max. reach at ground level mm 9,920
C Max. digging height mm 10,635
D Max. digging depth mm 3,535
E Min. reach at ground level mm 5,620
Min. swing radius of work
F mm 6,340
equipment
PC750, 800-7 01-3-2

(3)
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model PC750-7 PC750SE-7
Serial Number 20001 and up 20001 and up
Bucket capacity m3 3.1 4.0

Weight of machine kg 72,500 73,300
Max. digging depth mm 8,600 7,130
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
Max. dumping height mm 8,145 7,525
Performance
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: 2.8 Low speed: 2.8
High speed: 4.2 High speed: 4.2
Gradeability deg. 35 35
Ground pressure (standard double kPa {kg/cm }2
101.01 {1.03} 102.97 {1.05}
grouser shoe width: 710 mm)
Overall length mm 14,305 13,030
Overall width mm 4,335 4,335
Overall width of track mm 3,490 (4,210) 3,490 (4,210)
(when extended)
Overall height mm 4,660 4,615
Overall height to top of machine mm 4,000 4,000
Ground clearance of upper struc- mm 1,560 1,560
Dimensions
ture
Min. ground clearance mm 840 840
Tail swing radius mm 4,300 4,245
Min. swing radius of work equip- mm 6,060 5,645
ment
Height of work equipment mm 10,855 9,750
at min. swing radius
Length of track on ground mm 4,500 4,500
Track gauge (when extended) mm 2,780 (3,500) 2,780 (3,500)
Height of machine cab mm 3,560 3,560
01-4 PC750, 800-7

(3)
Model SAA6D140E-3
Type 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler (air cooled)
No. of cylinders – bore × stroke mm 6 – 140 × 165
Piston displacement l {cc} 15.24 {15,240}
Flywheel horsepower kW/rpm {HP/rpm} 338/1,800 {454/1,800}

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

Engine
Max. speed at no load rpm 1,980

Min. speed at no load rpm 825
Min. fuel consumption g/kWh {g/HPh} 196 {146.4}
Starting motor 24V, 11 kW

Alternator 24V, 50A
Battery 12V, 170 Ah × 2
Radiator core type CWX-4
Undercarriage
Carrier roller 3 on each side
Track roller 8 on each side
Track shoe Assembly-type double grouser, 47 on each side
Type Variable displacement piston type:

Hydraulic motor Control valve Hydraulic pump
HPV95+95, HPV95+95, gear type: SAR80+8
Delivery l /min Piston type: 490+490, gear type: 136+16
Set pressure MPa {kg/cm2} Piston type: 31.4 {320}, gear type: 2.9 {30}
Type × No. 4-spool + 5-spool type × 1
Control method Hydraulic
Travel motor Piston type (with brake valve, shaft brake):

× 2 (MSF-340VP-EH11)
Hydraulic system
Swing motor Piston type (with safety valve, shaft brake):

× 2 (KMF125AB-5)
Boom Arm ( 1, 2) Bucket ( 1)

( 1) PC750-7 PC750SE-7 PC750-7 PC750SE-7
Hydraulic cylinder
Cylinder type Double-acting piston

Inside diameter of cylinder mm 200 200 185 185 225
Outside diameter of piston rod mm 140 140 120 120 160
Stroke mm 1,950 2,250 1,610 1,610 1,420
Max. distance between pins mm 4,880 5,525 3,990 3,990 3,910
Min. distance between pins mm 2,930 3,275 2,380 2,380 2,490
Hydraulic tank Box-shaped, sealed with breather
Hydraulic filter Tank return side
Hydraulic cooler Air cooled (J4)
1. With cushion on head side 2. With cushion on bottom side
PC750, 800-7 01-5

Machine model PC750LC-7
Serial Number 20001 and up
Bucket capacity m3 3.1

Weight of machine kg 78,100
Max. digging depth mm 8,600
Max. vertical wall depth mm 5,575

Working ranges
Max. digging reach mm 13,740
Max. reach at ground level mm 13,460
Max. digging height mm 11,840
Max. dumping height mm 8,145

Performance
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: 2.8
High speed: 4.2

Gradeability deg. 35
86.3 {0.882}
Overall length mm 14,305
Overall width mm 4,455
Overall width of track mm 4,310
(when extended)
Overall height mm 4,660
Overall height to top of machine mm 4,000
Ground clearance of upper mm 1,560
structure
Dimensions
Min. ground clearance mm 840
Tail swing radius mm 4,300
Min. swing radius of work equip- mm 6,060
ment
Height of work equipment mm 10,855
Length of track on ground mm 5,020
Track gauge (when extended) mm 3,500
Height of machine cab mm 3,560
01-6 PC750, 800-7

Machine model PC750LC-7
Model SAA6D140E-3
Performance

Engine

Alternator 24V, 50A
Hydraulic pump
Undercarriage
Control valve

Hydraulic motor
× 2 (MSF-340VP-EH11)

× 2 (KMF125AB-5)
Hydraulic system
Boom ( 1) Arm ( 1, 2) Bucket ( 1)
Cylinder type Double-acting piston Double-acting piston Double-acting piston

Hydraulic cylinder
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, 800-7 01-7

Bucket capacity m3 3.4 4.3

Weight of machine kg 76,200 75,700
Max. digging depth mm 8,445 7,130
Max. vertical wall depth mm 5,230 4,080

Working ranges
Max. digging reach mm 13,660 12,265
Max. reach at ground level mm 13,400 11,945
Max. digging height mm 11,955 11,330
Max. dumping height mm 8,235 7,525

Performance
Max. digging force kN {kg} 362.8 {37,000} 430.5 {43,900}

Swing speed rpm 6.8 6.8
Swing max. slope angle deg. 16 16
Travel speed km/h Low speed: 2.8 Low speed: 2.8
High speed: 4.2 High speed: 4.2

Gradeability deg. 35 35
106.89 {1.09} 105.91 {1.08}
Overall length mm 13,895 13,030
Overall width mm 4,335 4,335
Overall width of track mm 3,490 (4,210) 3,490 (4,210)
(when extended)
Overall height mm 4,850 4,615
Overall height to top of machine mm 4,000 4,000
Ground clearance of upper mm 1,560 1,560

Dimensions
structure
Min. ground clearance mm 840 840
Tail swing radius mm 4,300 4,300
Min. swing radius of work equip- mm 5,985 5,645
ment
Height of work equipment mm 10,430 9,750
Length of track on ground mm 4,500 4,500
Track gauge (when extended) mm 2,780 {3,500} 2,780 {3,500}

Height of machine cab mm 3,640 3,640
01-8 PC750, 800-7

Model SAA6D140E-3
Performance

Engine

Alternator 24V, 50A
Undercarriage


× 2 (MSF-340VP-EH11)
Hydraulic system

× 2 (KMF125AB-5)
Boom Arm Bucket ( 1)

( 1) ( 1, 2) PC800-7 PC800SE-7
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, 800-7 01-9

Machine model PC750-7
Bucket capacity m3 4.5

Weight of machine kg 76,000
Max. digging depth mm 3,535
Working ranges
Max. vertical wall depth mm —

Max. digging reach mm 10,305
Max. reach at ground level mm 9,920
Max. digging height mm 10,635
Max. dumping height mm 7,180
Performance
Max. digging force kN {kg} 476.3 {48,600}

Swing speed rpm 6.8
Swing max. slope angle deg. 16
Travel speed km/h Low speed: 2.8
High speed: 4.2
Gradeability deg. 35
124 {1.26}
Overall length mm 9,865
Overall width mm 4,335
Overall width of track (when extended) mm 3,390 (4,110)
Overall height mm 5,640
Overall height to top of machine mm 4,000
Ground clearance of upper structure mm 1,560
Dimensions
Min. ground clearance mm 840

Tail swing radius mm 4,300
Min. swing radius of work equipment mm 6,340
Height of work equipment at mm 7,090
min. swing radius
Length of track on ground mm 4,500
Track gauge (when extended) mm 2,780 (3,500)
Height of machine cab mm 3,560
01-9-1 PC750, 800-7

(3)
Machine model PC750-7
Model SAA6D140E-3

Performance

Engine

Min. fuel consumption g/kWh {g/HPh} 196 {144}
Starting motor 24 V, 11 kW
Alternator 24 V, 50 A
Battery 12 V, 170 Ah × 2
Undercarriage


× 2 (MSF-340VP)
Hydraulic system

× 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 1,550 335
Max. distance between pins mm 4,340 4,130 4,275 1,235
Min. distance between pins mm 2,850 2,600 2,725 900
PC750, 800-7 01-9-2

(3)
GENERAL WEIGHT TABLE
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components
Unit: kg
Machine model PC750-7 PC750SE-7 PC750LC-7
Serial Number 20001 and up 20001 and up 20001 and up
Engine assembly 2,554 2,554 2,554

• Engine 1,720 1,720 1,720
• PTO (incl. lubricating piping) 500 500 500
• No. 1 pump 165 165 165
• No. 2 pump 150 150 150
• Control, PTO lubrication pump 19 19 19
Radiator assembly 260 260 260

Oil cooler assembly 200 200 200
Hydraulic tank (excl. hydraulic oil) 664 664 664
Revolving frame (incl. left and right decks) 6,960 6,960 6,960
Operator's cab 293 293 293
Swing machinery 490 × 2 490 × 2 490 × 2
Swing motor assembly 57 × 2 57 × 2 57 × 2
Travel motor assembly 130 × 2 130 × 2 130 × 2
L.H. 5-spool control valve 245 245 245
R.H. 4-spool control valve 240 240 240
Center swivel joint 69 69 69
Counterweight 9,800 9,800 9,800
Track frame assembly 19,845 19,854 20,626

• Center frame 5,550 5,550 5,550
• Track frame 2,630 × 2 2,630 × 2 2,880 × 2
• Carrier roller 51.8 × 6 51.8 × 6 51.8 × 6
• Track roller 136 × 16 136 × 16 136 × 18
• Idler cushion assembly 782 × 2 782 × 2 782 × 2
• Idler 450 × 2 450 × 2 450 × 2
• Final drive assembly 1,344 × 2 1,344 × 2 1,344 × 2
• Swing circle assembly 1,405 1,405 1,405
01-10 PC750, 800-7

Unit: kg
Machine model PC750-7 PC750SE-7 PC750LC-7
Serial Number 20001 and up 20001 and up 20001 and up
Track shoe assembly

• Narrow shoe (610 mm) 7,550 7,550 —
• Standard shoe (710 mm) 8,350 8,350 —
• Wide shoe (810 mm) 8,880 8,880 10,020
• Wide shoe (910 mm) 9,520 9,520 —
• Wide shoe (1,010 mm) 10,160 10,160 11,520
• Wide shoe (1,110 mm) — — 12,270
Boom assembly (excl. piping) 7,420 6,850 7,420

Arm assembly (excl. piping) 2,690 3,160 3,035
Bucket assembly (excl. piping) 2,960 3,435 2,960
Boom cylinder assembly 790 × 2 790 × 2 790 × 2
Arm cylinder assembly 881 497 × 2 881
Bucket cylinder assembly 506 933 506
Boom foot pin 45.2 × 2 45.2 × 2 45.2 × 2
Boom cylinder foot pin 33.8 × 2 33.8 × 2 33.8 × 2
Boom cylinder top pin 32.5 × 2 32.5 × 2 32.5 × 2
Boom-arm connecting pin 105 105 105
Arm cylinder foot pin 53.6 24 × 2 53.6
Arm cylinder top pin 30 24 × 2 30
Link-arm connecting pin 56.1 56.1 56.1
Link-bucket connecting pin 62.2 62.2 62.2
Bucket cylinder top pin 49.3 84.5 49.3
Bucket cylinder foot pin 25.3 43.8 25.3
Arm-bucket connecting pin 91.4 91.4 91.4
Link assembly 410.4 445 410.4
PC750, 800-7 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 × 2 490 × 2
Swing motor assembly 57 × 2 57 × 2
Travel motor assembly 130 × 2 130 × 2
L.H. 5-spool control valve 245 245
R.H. 4-spool control valve 240 240
Center swivel joint 69 69
Counterweight 12,000 12,000
Track frame assembly 19,854 19,854

• Center frame 5,550 5,550
• Track frame 2,630 × 2 2,630 × 2
• Carrier roller 51.8 × 6 51.8 × 6
• Track roller 136 × 16 136 × 16
• Idler cushion assembly 782 × 2 782 × 2
• Idler 450 × 2 450 × 2
• Final drive assembly 1,344 × 2 1,344 × 2
• Swing circle assembly 1,405 1,405
01-12 PC750, 800-7

Unit: kg
Track shoe assembly

• Narrow shoe (610 mm) 7,550 7,550
• Standard shoe (710 mm) 8,350 8,350
• Wide shoe (810 mm) — —
• Wide shoe (910 mm) — —
• Wide shoe (1,010 mm) — —
• Wide shoe (1,110 mm) — —
Boom assembly (excl. piping) 7,660 6,850

Arm assembly (excl. piping) 3,135 3,160
Bucket assembly (excl. piping) 3,540 3,840
Boom cylinder assembly 790 × 2 790 × 2
Arm cylinder assembly 497 × 2 497 × 2
Bucket cylinder assembly 545 933
Boom foot pin 45.2 × 2 45.2 × 2
Boom cylinder foot pin 33.8 × 2 33.8 × 2
Boom cylinder top pin 32.5 × 2 32.5 × 2
Boom-arm connecting pin 105 105
Arm cylinder foot pin 24 × 2 24 × 2
Arm cylinder top pin 24 × 2 24 × 2
Link-arm connecting pin 56.1 56.1
Link-bucket connecting pin 62.2 62.2
Bucket cylinder top pin 49.3 84.5
Bucket cylinder foot pin 25.3 43.8
Arm-bucket connecting pin 91.4 91.4
Link assembly 479 445
PC750, 800-7 01-13

GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS
01-14 PC750, 800-7

(1)
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PTO ......................................................... 10- 2 R.H. 4-SPOOL CONTROL VALVE ...........10- 66
PTO LUBRICATION SYSTEM................. 10- 3 STRAIGHT-TRAVEL VALVE ....................10- 72
POWER TRAIN ....................................... 10- 4 SWING MOTOR.......................................10- 75
SWING MACHINERY .............................. 10- 6 CENTER SWIVEL JOINT.........................10- 80
SWING CIRCLE ...................................... 10- 8 TRAVEL MOTOR .....................................10- 81
FINAL DRIVE .......................................... 10- 10 PPC CONTROL RELIEF VALVE..............10- 91
SPROCKET ............................................. 10-11-1 PPC ACCUMULATOR .............................10- 92
TRACK FRAME AND RECOIL SPRING . 10- 12 VALVE CONTROL....................................10- 93
IDLER ...................................................... 10- 14 WORK EQUIPMENT,
CARRIER ROLLER ................................. 10- 16 SWING PPC VALVE ...........................10- 94
TRACK ROLLER ..................................... 10- 17 TRAVEL PPC VALVE ...............................10-100
TRACK SHOE ......................................... 10- 18 SOLENOID VALVE...................................10-104
MOTOR GREASE PUMP ........................ 10- 23 HYDRAULIC CYLINDER .........................10- 110
HYDRAULIC TANK.................................. 10- 24 WORK EQUIPMENT................................10- 114
HYDRAULIC PUMP ................................ 10- 26 DIMENSIONS OF WORK EQUIPMENT ..10- 118
RETURN OIL FILTER.............................. 10- 56 AIR CONDITIONER .................................10-122
LINE OIL FILTER..................................... 10- 57 ENGINE CONTROL .................................10-123
PILOT OIL FILTER .................................. 10- 57 MACHINE CONTROL SYSTEM ..............10-129
DRAIN OIL FILTER.................................. 10- 58 MONITOR SYSTEM.................................10-158
L.H. 5-SPOOL CONTROL VALVE........... 10- 60 SENSORS................................................10-173
PC750, 800-7 10-1

(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PTO
PTO
1. PTO case Specifications

2. Driven gear (No. of teeth: 56) Lubricating oil: 13.5 l (EO30-CD)
3. Main shaft 56
4. Hub Reduction ratio: HPV95 + 95 shaft = 42 = 1.333
5. Connection plate
56
6. Driven gear (No. of teeth: 42) HPV95 + 95 shaft = 42 = 1.333
7. Breather
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
Backlash of gear pump spline Standard size Repair limit

8
(for SAR80 + 8) 0.273 – 0.374 —
Backlash between drive gear Adjust
9 0.2 – 0.74 —
and driven gear (for SAL63 + 8)
Backlash of main pump spline
10 0.07 – 0.18 —
(for HPV95 + 95)
10-2 PC750, 800-7

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 lubri-
3. Lubricating pipe cating pump (4). The lubricating oil inside PTO case
4. Control, PTO lubricating pump (SAR80 + 8) (1) passes through oil filter (5), is sent to top divider
5. Oil filter block (2), and is then divided to various parts of the
PTO to lubricate and cool the gears.
PC750, 800-7 10-3

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
10-4 PC750, 800-7

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, 800-7 10-5

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
10-6 PC750, 800-7

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
15. Drain plug
Specification
Reduction ratio:
20 + 97 × 19 + 97 = 35.716
20 19
Unit: mm
Backlash between swing Standard clearance Clearance limit

16
motor shaft and No. 1 sun gear 0.19 – 0.29 —
Backlash between No. 1 sun
17 0.19 – 0.51 0.90
gear and No. 1 planet gear
Backlash between No. 1
18 0.24 – 0.70 0.90
planet gear and ring gear
19 0.06 – 0.24 —
planet carrier and coupling
Backlash between No. 1 planet
20 0.38 – 0.78 1.10
carrier and No. 2 sun gear
Replace
21 0.17 – 0.52 1.00
22 0.21 – 0.64 1.10
planet gear and ring gear
Backlash between coupling
23 0.08 – 0.25 —
and swing pinion
Backlash between swing pin-
24 0 – 1.5 2.00
ion and swing circle
Clearance between plate
25 0.06 – 0.86 —
and coupling
Standard size Repair limit Repair hard

Wear of swing pinion oil seal chrome
26
contact surface 0 plating or
150 –0.100 — replace
PC750, 800-7 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: 65 l (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, 800-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
1. Level plug Specifications

2. Drain plug
Reduction ratio: – ( 13 + 68 ) × ( 19 + 69 ) × 69
3. Cover 13 19 19
4. No. 2 planetary carrier = –104.802
6. Drive gear (No. of teeth: 19)
8. No. 2 planet gear (No. of teeth: 24)
9. Hub
10. Sprocket
11. Floating seal
12. Case
13. Coupling
15. Travel motor
16. Idler gear (No. of teeth: 27)
17. No. 1 ring gear (No. of teeth: 68)
18. No. 1 planet gear (No. of teeth: 24)
19. Driven gear (No. of teeth: 69)
20. No. 2 ring gear (No. of teeth: 69)
10-10 PC750, 800-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
Backlash between No. 2 Standard clearance Clearance limit

21
planetary carrier and case 0.08 – 0.27 —
Backlash between drive gear
22 0.21 – 0.57 —
and No. 1 planetary carrier
23 gear and No. 1 planetary 0.24 – 0.91 —
carrier
24 0.23 – 0.68 —
Backlash between No. 2 plane-
25 0.28 – 0.87 —
tary carrier and No. 2 ring gear
Backlash between coupling Replace
26 0.38 – 0.72 —
and drive gear
Backlash between No. 1 ring
27 0.08 – 0.26 —
gear and case
28 gear and travel motor cou- 0.07 – 0.18 —
pling
29 0.15 – 0.62 —
gear and idler gear
Backlash between No. 1 ring
30 0.19 – 0.62 —
gear and idler gear
Backlash between driven
31 0.19 – 0.62 —
Wear of sprocket tooth
32 Repair limit: 6
shape
Rebuild or
Standard size Repair limit replace
33 Sprocket tooth width
114 108
PC750, 800-7 10-11

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm
Standard size Repair limit

1 Wear of tooth tip
403.6 391.6
Build-up welding
2 Thickness of tooth root 28.4 22.4
or replace
3 Width of tooth 114 108
4 Wear of tooth shape Repair limit: 6 (measure with sprocket tooth shape)
10-11-1 PC750, 800-7

(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET
SPROCKET TOOTH SHAPE OF REAL DIMENSION
a The above drawing is reduced to 50%. Enlarge it to 200% to return it to the full scale and make a copy on
an OHP sheet.
PC750, 800-7 10-11-2

(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
TRACK FRAME AND RECOIL SPRING

a The diagram shows the PC750-7.
1. Idler • The dimensions and number of track rollers may

2. Track frame differ according to the model, but the basic struc-
3. Carrier roller ture is the same.
4. Center frame
5. Final drive • No. of track rollers
6. Track roller
Model No. of rollers (each side)
7. Track shoe
8. Idler cushion PC750, 750SE-7
8
9. Front guard PC800, 800SE-7
PC750LC-7 9
10-12 PC750, 800-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
Standard shoe Unit: mm

Model
PC750-7 PC750SE-7 PC750LC-7 PC800-7 PC800SE-7
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
Tolerance Repair limit
size Rebuild or
Top-to-bottom width of idler +3 replace
10 Track frame 185 185 –2 190
guide
Idler support 180 185±0.5 175 Replace
+3 Rebuild or
Track frame 345 345 –2 355
Left-to-right width of idler replace
11
guide
Idler support 340 — 332

Free length Installation Installation Installation Replace
Free length
12 Recoil spring × OD length load load
489.8 kN 392 kN
1,553 × 308 1,290 —
{49,986 kg} {40,000 kg}
PC750, 800-7 10-13

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
IDLER
10-14 PC750, 800-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
Unit: mm
Outside diameter of protrud- Standard size Repair limit

1
ing part 875 —
Outside diameter of tread sur-
2 830 818 Rebuild or
face
replace
3 Depth of tread 22.5 28.5
4 Overall width 266 —
5 Width of tread 69.5 —
Standard Tolerance Standard Clearance

Clearance between shaft and size Shaft Hole clearance limit
6
bushing
–0.120 +0.361 0.401 –
110 1.5
–0.207 +0.281 0.568 Replace
Tolerance bushing
Standard Standard Interference
Interference between idler size Shaft Hole interference limit
7
and bushing
+0.087 –0.036 0.073 –
120 —
+0.037 –0.136 0.223
PC750, 800-7 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
3 Width of tread 68 — replace
4 Thickness of tread 57.6 47.6

5 Width of flange 17 —
Standard Tolerance Standard Interference

Interference between bearing size Shaft Hole interference limit
6
and support
0 0 –0.015 –
110 —
–0.015 –0.035 0.035
Replace
Interference between bearing +0.039 0 0.020 –
7 60 —
and shaft +0.020 –0.015 0.054
Standard clearance Clearance limit
8 Play of roller in axial direction
0 – 0.301 0.43
10-16 PC750, 800-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm

1 Outside diameter of flange
298 —
Outside diameter of tread sur-
2 255 243
face
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 —

Clearance between shaft and size Shaft Hole clearance limit
8
bushing
–0.140 +0.375 0.375 –
100 1.5
–0.207 +0.235 0.582 Replace
Tolerance bushing
Standard Standard Interference
Interference between roller size Shaft Hole interference limit
9
and bushing
+0.087 +0.020 0.017 –
107.6 —
+0.037 –0.015 0.102
PC750, 800-7 10-17

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE (1/2)

TRACK SHOE
a P portion shows the link of bushing press-fitting end.
10-18 PC750, 800-7

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 —
Standard size Repair limit Repair or
3 Link height
156 143 replace
Thickness of link metal

4 39.3 26.3
(bushing press-fitting portion)
5 234.95 Replace
6 Shoe bolt pitch 184.2
7 76.2
Inside
8 133.6
width
Overall Repair or
9 Link 73
width replace
Tread
10 65
width
11 Protrusion of pin 4.5
12 Protrusion of regular bushing 10.8
13 Overall length of pin 320.4 Adjust or
14 Overall length of bushing 225.8 replace
15 Thickness of bushing metal 15.75

16 Thickness of spacer 12.45
17 Bushing 130 – 217 kN {13.3 – 22.1 ton}
Press-fitting Regular
18 312 – 350 kN {31.8 – 35.7 ton} —
force pin
Master
19 249 – 294 kN {25.9 – 30 ton}
pin
: Dry type track link
PC750, 800-7 10-19

(1)
(2/2)
a P portion shows the link of bushing press-fitting end.
10-20 PC750, 800-7

Unit: mm
Tightening torque Additinal tightening

a. Regular (Nm {kgm}) angle (deg.)
link
784±78 {80±8} 120±10
Shoe bolt Retighten
20 Tightening torque Additinal tightening Lower limit torque
b. Master (Nm {kgm}) angle (deg.) (Nm {kgm})
link
— — —
No. of shoes (each side) PC750, 800-7: 47, PC750LC-7: 51 —
Tolerance Standard
Standard size
Interference between bush- Shaft Hole interference
21
ing and link
+0.472 +0.087
87.5 0.285 – 0.472
+0.372 0
Interference between regular +0.596 +0.074
22 55.2 0.422 – 0.596
pin and link +0.496 0
Tolerance Standard
Standard size
Clearance between regular Shaft Hole clearance
23
pin and bushing
+0.05 +1.286 Adjust or
56 0.736 – 1.236
–0.05 +0.786 replace
Tolerance Standard
Standard size
Interference between master Shaft Hole interference
24 pin and link
+0.442 +0.074
55.2 0.338 – 0.442
+0.412 0
Tolerance Standard
Standard size
Clearance between master Shaft Hole clearance
25 pin and bushing
+0.296 +1.036
56 0.24 – 0.84
+0.196 +0.536
: Dry type track link
PC750, 800-7 10-21

DOUBLE SHOE
Unit: mm

1 Height
50 25
2 Height 50
3 Thickness 20 Rebuild or
4 39 replace
Length at bottom
5 —
6 30
Length at top
7 30
10-22 PC750, 800-7

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 (4) and
3. Cover grease chamber (6). As the grease level in
4. Air chamber grease chamber (6) lowers, follower plate (5) is
5. Follower plate pulled down to push down the grease sticking to
6. Grease chamber the rim of grease chamber (6).
7. Grease tank
8. Wing nut
PC750, 800-7 10-23

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Hydraulic tank Specifications

2. Strainer Tank capacity : 729 l
3. Oil filler cap Amount of oil inside tank : 482 l (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
9. Hydraulic oil temperature sensor {0 – 0.005 kg/cm2}
10-24 PC750, 800-7

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, 800-7

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, 800-7 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, 800-7

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
PA1 : Main pump pressure IN port Pd : Jet sensor downstream pressure IN port
Pe2 : TVC valve output pressure front, Pecn : CO, NC valve output pressure detection port
rear interconnection port Pdr : Servo valve drain OUT port
Psv : Servo basic pressure IN port
PC750, 800-7 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 intercon-
PA2 : Main pump pressure IN port nection port
Psv : Servo basic pressure IN port Pdr : Servo valve drain OUT port
10-30 PC750, 800-7

4. Servo valve
• No. 1 pump front servo valve
PA2 : Main pump pressure OUT port

Pdr : CO, NC valve drain port
Pecn : CO, NC valve output pressure IN port
PC750, 800-7 10-31

• No. 1 pump rear servo valve

Pdr : CO, NC valve drain port
Psv2 : Servo basic pressure OUT port
10-32 PC750, 800-7

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 between pump dis-
charge amount Q and input signal Pecn to the servo
valve is as shown in the graph on the right. Q varies
in proportion to Pecn.
PC750, 800-7 10-33

Operation
1) Operation in direction of increase of pump discharge amount (max. angle)
• The control pump pressure Psv is taken to port At the same time, port a is interconnected with
a. port h, so the oil flows through port i to servo
Signal pressure Pecn from the NC valve is piston chamber j, pushes servo piston (19) to
taken from port b to chamber c. the left, increases the swash plate angle in the
• When signal pressure Pecn rises, control piston main piston pump and increases the pump dis-
(8) is pushed to the left by the hydraulic pressure charge amount.
in chamber c, and stops at a point where it bal- • When servo piston (19) moves, arm (6) rotates
ances the pressure of springs (4) and (4A). clockwise with its center at pin (7). Guide spool
At the same time, arm (6) uses servo piston (19) (13) is moved to the right and closes port a, port
as a fulcrum and sways to the left in the same d and port h, so the discharge increases by an
way as control piston (8). This moves guide amount that matches signal pressure Pecn.
spool (13) to the left.
• When guide spool (13) moves, port a and port d
are closed and port d is connected to drain
chamber e. As a result, servo piston chamber f is
also interconnected with chamber e through port
g and port d.
10-34 PC750, 800-7

2) Operation in direction of decrease of pump discharge amount (min. angle)
• When signal pressure Pecn goes down, control • When servo piston (19) moves, arm (6) rotates
piston (8) moves to the right and stops at a point counterclockwise with its center at pin (7). Guide
where the hydraulic pressure in chamber c bal- spool (13) is moved to the left and closes port a,
ances the pressure of springs (4) and (4A). port d and port h, so the discharge decreases by
At the same time, arm (6) uses servo piston (19) an amount that matches signal pressure Pecn.
as a fulcrum and sways to the right in the same
way as control piston (8). This moves guide
spool (13) to the right.
• When guide spool (13) moves, port a and port h
are closed and port h is connected to drain
chamber e. As a result, servo piston chamber j is
also interconnected with chamber e through port
i and port h.
At the same time, port a is interconnected with
port d, so the oil flows through port g to servo
piston chamber f, pushes servo piston (19) to
the right, decreases the swash plate angle in the
main piston pump and decreases the pump dis-
charge amount.
PC750, 800-7 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, 800-7

Operation and function of TVC valve

1) When command current value from controller is small in A and E mode
Function Operation
• When the power mode is at A mode or E mode, • The command current sent from the controller
the pump discharge amount is controlled to the actuates solenoid push pin (9) and spool (2)
optimum amount by the command current sent moves. When this happens, the piston stops at a
from the controller in accordance with the varia- point where it balances the total of the force of
tion in the engine speed. spring (1), the force of push pin (9), and the force
• When the pump prolix switch is ON, the pump of TVC output pressure Pe acting on piston (3).
discharge amount is controlled according to the The command current at this point is small, so
pump discharge pressure (load) by hydraulic spool (2) is balanced at the bottom.
sensing which follows a constant pump absorp- As a result, port a and port b are almost com-
tion torque. pletely open, so the pressure oil from the control
pump is almost all output as TVC output pres-
a For details, see MACHINE CONTROL SYS- sure Pe.
TEM. In thi s way, th e p ump di s cha r ge amou nt
becomes the maximum.
PC750, 800-7 10-37

2) When command current value from controller is large in A and E mode
Operation
• The command current sent from the controller
actuates solenoid push pin (9) and spool (2)
moves. When this happens, the piston stops at a
point where it balances the force of spring (1).
The command current at this point is large, so
spool (2) is balanced at the top.
As a result, the flow of oil from the control pump
at port a and port b is throttled. At the same
time, the area of the opening at port b and port c
(drain port) becomes larger.
In this way, TVC output pressure Pe goes down,
and the pump discharge amount decreases.
10-38 PC750, 800-7

3) When pump load is small in pump prolix switch ON
• If the pump prolix switch is turned ON, solenoid

push pin (9) is pushed up to heighten the set
pressure of spring (1), and then spring (1) is kept
under this condition.
• As a result, the pump absorption torque be-
comes constant, so TVC output pressure Pe (=
pump discharge amount) is controlled by the
pump discharge pressure.
• Main pump discharge pressures PA1 and PA2
are low, so spool (2) is pushed down fully by
spring (1). As a result, control pump discharge
pressure Psv and TVC valve output pressure Pe
are equal.
At this point, TVC valve output pressure Pe
becomes the maximum, and the main pump dis-
charge amount is also the maximum.
PC750, 800-7 10-39

4) When pump load is large in pump prolix switch ON
• When main pump discharge pressure PA1 (or

PA2) increases, spool (2) is moved up by piston
(4) or piston (6). As a result, the flow of oil from
port a to port b is throttled by the notch in the
spool. At the same time, the area of the opening
at port b and port c (drain port) becomes larger.
In this way, TVC output pressure Pe goes down,
and the pump discharge amount decreases.
10-40 PC750, 800-7

6. No. 1 pump front CO, NC valve
10-42 PC750, 800-7

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 inter-
connection port
Pc : CO selector port
Pd : Jet sensor downstream pressure IN port
Pdr2 : CO, NC valve drain OUT port
Pecn : CO, NC valve output pressure OUT port
PC750, 800-7 10-43

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

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 inter-
connection port
Pe2 : TVC valve output pressure IN port
Pc : CO selector pilot port
Pd : Jet sensor downstream pressure IN port
Pdr1 : TVC valve drain IN port
Pdr2 : CO, NC valve drain OUT port
Psv1 : Servo basic pressure IN port
Psv2 : Servo basic pressure OUT port
Pecn : CO, NC valve output pressure OUT port
PC750, 800-7 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 operations • Spool (4) is being pushed down fully by spring
and the main pump discharge pressure rises to a (3).
point close to relief pressure, the cut-off function As a result, port a and port b are fully open and
of the CO valve acts to reduce the pump dis- TVC valve output pressure Pe and CO valve
charge in order to reduce relief loss. output pressure Pec are equal.
• At the same time, it has a cut-off cancel function In this way, CO valve output pressure Pec
actuated by the pilot pressure from the heavy-lift becomes the maximum and the main pump dis-
solenoid valve. charge amount also becomes the maximum.
• 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, 800-7

2) When main pump discharge pressure becomes close to relief pressure
• If the load increases and main pump discharge

pressure PA comes close to the relief pressure,
main pump discharge pressure PA pushes pis-
ton (5). At the same time, CO valve output pres-
sure Pec pushes piston (5), and spool (4) moves
up.
As a result, the flow of oil from port a to port b is
throttled by the notch in the spool, and the area
of the opening at port b and port c (drain port)
becomes larger.
In this way, CO valve output pressure Pec goes
down, and the pump discharge amount
becomes the minimum.
PC750, 800-7 10-47

3) When cut-off function is canceled by heavy-lift solenoid valve
• When the heavy-lift solenoid valve is excited and

is switched, pilot pressure Pc is sent to the port,
and piston (2) is pushed down fully.
For this reason, seat (6) contacts seat (7) and
spool (4) is locked.
As a result, main pump discharge pressure PA
goes up, but even when it reaches the relief
pressure, spool (4) is not actuated, so CO valve
output pressure Pec remains at the maximum.
10-48 PC750, 800-7

Function and operation of NC valve

1) When control valve is at neutral
Function Operation
• The NC valve controls the main pump discharge • Jet sensor differential pressure (Pt – Pd) be-
amount according to the amount that the control comes the maximum, and the force of jet sensor
valve spool is operated. This flow control function output pressure Pt pushing piston (10) becomes
reduces the neutral loss and fine control loss. larger than the total of the force of spring (12)
• The NC valve is controlled by balancing the total and the force of jet sensor output pressure Pd
of the jet sensor output pressure Pt and the NC pushing the bottom of spool (11).
valve output pressure Pecn with the total of the As a result, spool (11) is pushed down, so the
force of NC valve spring (12) and the jet sensor flow to port c and port b is throttled, and the
output pressure Pd. area of the opening of port b and port a (drain
• The jet sensor picks up the flow of oil returning to port) becomes larger. In this way, NC valve out-
the tank through the control valve and takes put pressure Pecn becomes the minimum, and
them as Pt and Pd of the NC valve. the main pump discharge amount also becomes
the minimum.
PC750, 800-7 10-49

2) When control lever is operated
• When the control valve is moved, the jet sensor

differential pressure (Pt – Pd) goes down in ac-
cordance with the movement of the control valve.
Spool (11) is pushed up, and the area of the
opening of port c and port b becomes larger.
In this way, NC valve output pressure Pecn
becomes larger and the discharge amount from
the main pump increases. In other words, the
pump discharge amount increases according to
the amount the control lever is operated.
10-50 PC750, 800-7

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
PC750, 800-7 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, 800-7

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, 800-7 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, 800-7

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, 800-7 10-55

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RETURN OIL FILTER
RETURN OIL FILTER
1. Cover Outline
2. Spring There are two return oil filters installed to the rear face
3. Bypass valve of the hydraulic tank. They remove the dirt and dust in
4. Bypass valve spring the return oil.
5. Element
6. Housing Specifications
• Bypass valve set pressure:
A. From control valve 0.15 ± 0.03 MPa {1.5 ± 0.3 kg/cm2}
B. To hydraulic tank
10-56 PC750, 800-7

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
PC750, 800-7 10-57

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRAIN OIL FILTER
DRAIN OIL FILTER
1. Cartridge
2. Safety valve
3. Bracket
10-58 PC750, 800-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD L.H. 5-SPOOL CONTROL VALVE
L.H. 5-SPOOL CONTROL VALVE
P : 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 : Plug
B2 : To swing motor (Port MB)
B3 : To arm cylinder head
B4 : Plug (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)
10-60 PC750, 800-7

PC750, 800-7 10-61

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
10-62 PC750, 800-7

10-64 PC750, 800-7

Unit: mm

Free length Installation Installation Installation
Main relief valve, main valve Free length
1 × OD length load load
spring
394.2 N 315.2 N
34.7 × 10.1 32.5 —
{40.2 kg} {32.2 kg}
Jet sensor relief valve, 30 N 24.3 N
2 34.5 × 8.8 29.4 —
pilot poppet spring {3.1 kg} {2.5 kg}
Jet sensor relief valve, main 49 N 39.2 N
3 37.4 × 11.4 33 — Replace
valve spring {5.0 kg} {4.0 kg}
spring if dam-
431 N 345 N aged 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}
Check valve spring 18.8 N 15.1 N
8 65.3 × 14 46 —
(throttle valve) {1.92 kg} {1.54 kg}
PC750, 800-7 10-65

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)
10-66 PC750, 800-7

PC750, 800-7 10-67

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
10-68 PC750, 800-7

10-70 PC750, 800-7

Unit: mm

Main relief valve, main valve Free length
1 × OD length load load
spring
394.2 N 315.2 N
34.7 × 10.1 32.5 —
{40.2 kg} {32.2 kg}
2 34.5 × 8.8 29.4 —
pilot poppet spring {3.1 kg} {2.5 kg}
Replace
3 37.4 × 11.4 33 — spring if dam-
main valve spring {5.0 kg} {4.0 kg}
aged or
431 N 345 N deformed
4 Spool return spring 69.9 × 57 63 —
{44 kg} {35.2 kg}
0N
5 Spool return spring 75 × 37 74.5 — 0 N {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, 800-7 10-71

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
10-72 PC750, 800-7

1. Orifice
2. Check valve
3. Spring
4. Spool return spring
5. Body
6. Spool
7. Cover
PC750, 800-7 10-73

Function
• When the travel is operated at the same time as
the boom, arm, or bucket, the pressure oil flow-
ing 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 sup-
plied 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 de-
viation.
Operation
When travel is operated independently (straight-
travel solenoid valve de-energized)
• The straight-travel solenoid valve is de-ener-
gized, so no pilot pressure flows, and spool (6)
remains pushed to the right.
• Because of this, port P2 (left travel circuit) and
port P1 (right travel circuit) are not interconnect-
ed, and each circuit remains independent.
When travel and work equipment are operated at

same time (straight-travel solenoid valve excited)
• The straight-travel solenoid valve is excited, so
the pilot pressure flows and spool (6) is pushed
to the left.
• Because of this, port P2 and port P1 are inter-
connected, so the amount of oil supplied to the
left and right travel motors is the same. As a re-
sult, the left and right travel motors both rotate at
the same speed, so there is no travel deviation.
10-74 PC750, 800-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
KMF125AB-5
B : From swing lock solenoid valve 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, 800-7 10-75

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
10-76 PC750, 800-7

Unit: mm

Free length
Installed Installed Installed
× Outside Free length
1 Check valve spring length load load If damaged or
diameter
deformed,
3.5 N 2.8 N replace spring
62.5 × 20.0 35 —
{0.36 kg} {0.29 kg}
13.7 N 10.8 N
2 Shuttle valve spring 16.4 × 8.9 11.5 —
{1.4 kg} {1.1 kg}
PC750, 800-7 10-77

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 dam-
age the motor.
To prevent this, the abnormally high pressure oil
is relieved to port S from the outlet port of the
motor (high-pressure side) to prevent any dam-
age.
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 generat-
ed in the motor, and the motor starts to ro-
tate. The oil from the outlet port of the motor
passes from port MA thought the control
valve and returns to the tank. (Fig. 1)
2) When stopping swing

• When the swing control lever is returned to
neutral, the supply of pressure oil from the
pump to port MA is stopped. With the oil from
the outlet port of the motor, the return circuit
to the tank is closed by the control valve, so
the pressure at port MB rises. As a result, ro-
tation 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.
10-78 PC750, 800-7

Operation of swing brake

1) When swing brake solenoid valve is de-ener-
gized
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 connected to the
tank circuit.
As a result, brake piston (6) is pushed down by
brake spring (7), pushes disc (5) and plate (4)
together, and the brake is applied.
2) When swing brake solenoid valve is excited

When the swing brake solenoid valve is ener-
gized, the valve is switched, and pressurized oil
from the control valve enters port B and flows to
brake chamber a.
The pressurized oil entering chamber a over-
comes brake spring (7) and pushes brake piston
(6) up. As a result, disc (5) and plate (4) are sep-
arated and the brake is released.
PC750, 800-7 10-79

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
Clearance between rotor and Standard size Standard clearance Clearance limit
6 Replace
shaft 110 0.056 – 0.105 0.111
10-80 PC750, 800-7

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
P1 : From control valve Rated pressure : 31.4 MPa {320 kg/cm2}
P2 : From control valve Rated speed : 1st 1,423 rpm
PI : From travel speed solenoid valve (at 500 l /min.)
T : To hydraulic tank : 2nd 2,258 rpm
(at 500 l /min.)
Brake release pressure : 1.8 MPa {18.4 kg/cm2}
PC750, 800-7 10-81

1. Travel motor, travel speed selector valve, relief valve
1. Travel speed selector valve 2. Relief valve

1a. Spool 2a. Shockless piston
1b. Spring 2b. Poppet
10-82 PC750, 800-7

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, 800-7 10-83

1-1 Motor
• There are 9 pistons (7) assembled in cylinder

block (6). The end face of the cylinder block has
a spherical surface and is in contact with valve
plate (5), which has two half-moon shaped ports
(divider valve for high/low speed selector).
• The fixed surface (contact surface with the motor

case) forming the non-sliding surface of rocker
cam (14) has two faces. The high/low speed vol-
ume selection for this motor is carried out by fix-
ing each face to provide large capacity (low
speed) or small capacity (high speed).
The angling operation of rocker cam (14) is car-
ried out by actuating control piston (10) with the
self-pressure through the speed selector valve
when the motor is being driven, and this angles
the rocker cam.
There are two control pistons each for the high/
low pressure divider ports of valve plate (5), and
these provide propulsion force to the rocker
cam.
10-84 PC750, 800-7

1-2 Speed selector valve
Operation
1) At low speed (pilot pressure PI = 0)
• When pilot pressure PI from the control pump is

0, spool (1a) of travel speed selector valve (1) is
not switched.
In this condition, the oil from the chamber of
control piston (10) passes through spool (1a)
and is drained into the motor case. There is no
angle propulsion force acting on rocker cam
(14), so the low-speed surface is kept in a static
condition.
PC750, 800-7 10-85

2) At high speed (automatic 2nd)
• When the pilot signal is ON, pilot pressure PI goes to the control piston chamber. Rocker
from the control pump acts on travel speed se- cam (14) overcomes moment Mx with
lector valve (1) and the capacity is automatically hydraulic force from propulsion force Fc of
changed by the drive pressure of the travel mo- control piston (10). It rotates and holds the
tor. moment balance at the high speed surface
and is held in position (Mx < Fc, L).
Balance of force for travel speed selector valve ii) When operating the steering or traveling
F1 [Force pushing spool (1a) to right (high- uphill, if the motor drive pressure is high, and
speed side)] = A (area of spool (1a) receiv- it goes above the set pressure, the condition
ing pressure) × PI becomes F1 < F2, and spool (1a) is pushed
F2 [Force pushing spool (1a) to left (low-speed to the left.
side)] = A (area of spool (1a) receiving pres- When this happens, the main oil pressure
sure) × PH (motor drive pressure) + force of (M1, M2) passes through spool (1a) and is
spring (1b) drained to the motor case. This creates the
low-speed condition in the same way as
i) When traveling on level ground, if the travel when PI = 0.
motor drive pressure is low, the condition
becomes F1 > F2, and spool (1a) is pushed
to the right.
When this happens, the main oil pressure
(M1, M2) passes through spool (1a) and
10-86 PC750, 800-7

1-3 Parking brake
The parking brake is a hydraulic release, wet

type, multiple disc negative brake. The release
pressure employs a self-pressure release
method using the travel motor drive pressure
through the oil passage in the counterbalance
valve spool of the travel brake valve.
When the machine is traveling, the drive pres-

sure is sent to port P of the parking brake circuit,
acts on the piston in the brake cylinder chamber,
overcomes the force of the spring and releases
the brake.
When the machine is parked or stopped, the
counterbalance valve spool returns to neutral,
and the oil in the cylinder chamber is released to
the tank through the counterbalance valve
spool, so the brake is applied by the force of the
spring to mechanically lock the motor shaft and
hold the machine in position.
When parking brake is ON

When the travel lever is placed in neutral, the
counterbalance valve spool returns to the neu-
tral position and parking brake circuit P is
closed.
The pressurized oil in chamber e of the brake
piston passes through the counterbalance valve
spool, is drained to the tank, and brake piston
(18) is pushed fully to the left by force Fs of
spring (19), and the brake is applied.
When parking brake is OFF

When the travel lever is operated, the pressur-
ized oil from the pump actuates the counterbal-
ance valve spool, opens the circuit to the
parking brake, and flows into chamber e of
brake piston (18). It overcomes the force of
spring (19), and pushes brake piston (18) to the
right.
When this happens, the force pushing plate (17)
and disc (16) together is lost, so the plate and
disc separate and the brake is released.
PC750, 800-7 10-87

1-4 Relief valve
1. Shockless piston
2. Poppet
3. Poppet orifice
4. Relief housing orifice
5. 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 pop-
pet (2) becomes area S1 of the poppet seat.
For this reason, it has a much larger pressure-
receiving area than the pressure-receiving area
when it is set (S1 – S2), so the relief actuating
pressure becomes a low pressure of approx.
15.7 MPa {160 kg/cm2}.
This condition is maintained until the movement
of shockless piston (1) is completed (approx.
0.25 sec).
2) When movement of shockless piston is com-

pleted (2nd stage)
The pressure in the relief valve spring chamber
rises, the pressure on both sides of poppet (2)
becomes the same, and it becomes the speci-
fied set pressure.
a Set pressure and amount of adjustment

Amount of adjustment for one turn:
Approx. 7.8 MPa {80 kg/cm2}
10-88 PC750, 800-7

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 ma-
chine makes it try to travel at a speed faster than
the rotation of the motor.
For this reason, if the machine is traveling with Specification
the engine running at low speed, the motor will Safety valve set pressure: 34 MPa {350 kg/cm2}
rotate under no load or may run away, which is Counterbalance switching pressure:
extremely dangerous. 1.0 ± 0.1 MPa {10 ± 1 kg/cm2}
To prevent this, this valve controls the amount of Check valve switching pressure:
oil on the return side in order to keep the valve 0.02 ± 0.01 MPa {0.2 ± 0.1 kg/cm2}
pressure constant, and makes it possible to
carry out travel operations which match the oil
delivery from the motor.
PC750, 800-7 10-89

Operation when oil is supplied

• When the travel lever is operated, the pressu-
rized oil from the control valve is supplied to port
P1. It pushes open check valve (5a) and flows
from motor inlet port M1 to motor outlet port M2.
However, the motor outlet port is closed by
check valve (5b) and spool (3), so the pressure
at the supply side rises.
• The pressurized oil at the supply side flows from

orifice a in spool (3) to chamber A. When the
pressure in chamber A goes above the spool
switching pressure, spool (3) is pushed to the
left.
As a result, port M2 and port P2 are connected,
the outlet port side of the motor is opened, and
the motor starts to rotate.
Operation of brake when traveling downhill

• If the machine tries to run away when traveling
downhill, the motor will turn under no load, so the
pressure at the motor inlet port will drop, and the
pressure in chamber A through orifice a will also
drop.
When the pressure in chamber A drops below
the spool switching pressure, spool (3) is
returned to the right by spring (2), and outlet port
M2 is throttled.
As a result, the pressure at the outlet port side
rises, resistance is generated to the rotation of
the motor, and this prevents the machine from
running away.
In other words, spool (3) moves to a position
where the pressure at outlet port M2 balances
the pressure at the inlet port and the force gen-
erated by the weight of the machine. It throttles
the outlet port circuit and controls the travel
speed according to the amount of oil discharged
from the pump.
10-90 PC750, 800-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC CONTROL RELIEF VALVE
PPC CONTROL RELIEF VALVE
1. Valve body Specifications

2. Check valve spring +0.3 +3
Set pressure: 3.1 0 MPa {32 0 kg/cm2} (at 135 l/min)
3. Check valve
4. Relief valve
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

Free length Installation Installation Free Installation
5 Check valve spring × OD length load length load Replace
70.6 N 5.65 N
56 × 21.4 37 —
{0.72 kg} {0.58 kg}
PC750, 800-7 10-91

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 en-
gine 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 com-
pressed by the oil pressure in chamber B.
• If the PPC valve is operated, the oil pressure in
chamber B becomes less than 2.9 MPa {30 kg/
cm2}, so the bladder expands under the pressure
of the nitrogen gas in chamber A. The oil enter-
ing chamber B is sent as the pilot pressure to ac-
tuate the main control valve.
10-92 PC750, 800-7

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
[10] Swing left
[11] Neutral
[12] Travel REVERSE
[13] Travel FORWARD
[14] LOCK
[15] FREE
PC750, 800-7 10-93

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT, SWING PPC VALVE
WORK EQUIPMENT, SWING PPC VALVE
P. From control pump P2. Left: Arm OUT, Right: Boom LOWER
T. To hydraulic tank P3. Left: Swing left, Right: Bucket DUMP
P1. Left: Arm IN, Right: Boom RAISE P4. Left: Swing right, Right: Bucket CURL
10-94 PC750, 800-7

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
10-96 PC750, 800-7

Unit: mm

Free length
11 Centering spring (for P3, P4) × OD length load load
Replace
17.6 N 13.7 N
42.48 × 15.5 34 — spring if
{1.8 kg} {1.4 kg}
damaged or
16.6 N 13.2 N deformed
12 Metering spring 26.7 × 8.14 24.9 —
{1.69 kg} {1.35 kg}
9.8 N 7.8 N
13 Centering spring (for P1, P2) 38.71 × 15.5 34 —
{1 kg} {0.8 kg}
PC750, 800-7 10-97

Operation
1) At neutral
Ports A and B of the control valve and ports P1,
P2, P3, and P4 of the PPC valve are connected
to drain chamber D at the bottom. (Fig. 1)
2) Fine control (neutral o fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed. Spool (1) is also pushed
by metering spring (2) and moves down.
When this happens, port P1 is shut off from
drain chamber D. At almost the same time, it is
connected to pump pressure chamber PP, and
the pilot pressure of the control pump is sent
from port P1 to port A.
When the pressure at port P1 rises, spool (1) is
pushed back. Port P1 is shut off from pump
pressure chamber PP. At almost the same time,
it is connected to drain chamber D, so the pres-
sure at port P1 escapes.
As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure of port P1.
The relationship of the positions of spool (1) and
body (10) does not change until retainer (9) con-
tacts spool (1).
Therefore, metering spring (2) is compressed in
proportion to the travel of the control lever, so
the pressure at port P1 also rises in proportion
to the travel of the control lever.
In this way, the spool of the control valve moves
to a position where the pressure of chamber A
(same as pressure at port P1) and the force of
the return spring of the control valve spool are
balanced.
10-98 PC750, 800-7

3) Fine control (control lever returned)

When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
Because of this, port P1 is connected to drain
chamber D, and the pressurized oil at port P1 is
released.
If the pressure at port P1 drops too much, spool
(1) is pushed down by metering spring (2), so
port P1 is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, so the pressure at port
P1 supplies the pump pressure until the pres-
sure recovers to a pressure equivalent to the
position of the lever.
When the control valve returns, oil in drain
chamber D flows in from the valve on the side
that is not moving. It passes through port P2 and
goes to chamber B to charge the oil.
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), port P1 is
shut off from drain chamber D, and is connected
to pump pressure chamber PP. Therefore, the
pilot pressure oil from the control pump flows to
chamber A from port P1 to push the control
valve spool.
The return oil from chamber B passes from port
P2 and flows to drain chamber D.
PC750, 800-7 10-99

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
P : From control pump

T : To tank
P1 : Left travel forward
P2 : Left travel reverse
P3 : Right travel forward
P4 : Right travel reverse
10-100 PC750, 800-7

1. Plate 5. Centering spring

2. Body 6. Metering spring
3. Piston 7. Valve
4. Collar 8. Bolt
Unit: mm
Basic dimension Allowable limit

Free length
Installed Installed Installed
× Outside Free length
9 Metering spring length load load If damaged or
diameter
deformed,
16.6 N 13.7 N replace spring
26.7 × 8.14 24.9 —
{1.69 kg} {1.40 kg}
107.9 N 86.3 N
10 Centering spring 48.57 × 15.5 32.5 —
{11 kg} {8.8 kg}
PC750, 800-7 10-101

Operation
1. At neutral
• Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)
2. During fine control (neutral o fine control)

• When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed by
metering spring (2) and moves down.
• When this happens, fine control hole f is shut off
from drain chamber D. At almost the same time,
it is connected to pump pressure chamber PP,
and the pilot pressure of the control pump is sent
from port A through fine control hole f to port P1.
• When the pressure at port P1 rises, spool (1) is
pushed back. Fine control hole f is shut off from
pump pressure chamber PP. At almost the same
time, it is connected to drain chamber D to re-
lease the pressure at port P1.
• As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure of port P1.
• The relationship in the position of spool (1) and
body (10) (fine control hole f is in the middle be-
tween drain hole D and pump pressure chamber
PP) does not change until retainer (9) contacts
spool (1).
• Therefore, metering spring (2) is compressed in
proportion to the travel of the control lever, so the
pressure at port P1 also rises in proportion to the
travel of the control lever.
• In this way, the control valve spool moves to a
position where the pressure of chamber A (same
as pressure at port P1) and the force of the return
spring of the control valve spool are balanced.
(Fig. 2)
10-102 PC750, 800-7

3. Fine control (control lever returned)

• When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
Because of this, fine control hole f is connected
to drain chamber D, and the pressurized oil at
port P1 is released.
• If the pressure at port P1 drops too much, spool
(1) is pushed up by metering spring (2), so fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, so the pressure at port P1
supplies the pump pressure until the pressure re-
covers to a pressure equivalent to the position of
the lever.
• When the control valve returns, oil in drain cham-
ber D flows in from fine control hole f ’ of the valve
on the side that is not moving. It passes through
port P2 and enters chamber B to fill the chamber
with oil. (Fig. 3)
4. At full stroke
• Disc (5) pushes down piston (4), and retainer (9)
pushes down spool (1). Fine control hole f is shut
off from drain chamber D, and is connected to
pump pressure chamber PP.
• Therefore, the pilot pressure oil from the main
pump passes through fine control hole f and
flows to chamber A from port P1 to push the con-
trol valve spool.
• The return oil chamber B passes from port P2
through fine control hole f ’ and flows to drain
chamber D. (Fig. 4)
PC750, 800-7 10-103

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
For resetting CO, straight travel, heavy lifting, pushing up machine, travel speed
(at center of machine body)
1. 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 boom LOWER 2-stage safety valve
4. Machine push-up solenoid valve A3 : To main valve (Relief valve)
5. Travel speed solenoid valve A4 : To straight travel valve
A5 : To left and right travel motor
P1 : From control pump
ACC : Plug
PPC : Plug
10-104 PC750, 800-7

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 ac-
tuator 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), sole-
noid (3) is energized.
For this reason, spool (5) is pushed to the right
in the direction of the arrow.
As a result, the pressurized oil from the control
pump flows from port P through the inside of
spool (5) to port A, and then flows to the actua-
tor. At the same time, port T is closed, and this
stops the oil from flowing to the tank.
PC750, 800-7 10-105

For swing holding brake (on right side of machine body), for safety lock (under cab)
For swing holding brake For safety lock

1. Swing holding brake solenoid valve 1. Safety lock solenoid valve
T : To tank T : To tank
A : To front and rear swing motors A : To port P of work equipment PPC valve
P : From control pump To port P of travel PPC valve
10-106 PC750, 800-7

1. Connector 7. Spool
2. Solenoid 8. Body
3. Variable iron core 9. Plug
4. Body 10. Spring
5. Plug 11. Spool
6. Spring
Operation
• No signal current flows from the controller, so so-
lenoid (2) is de-energized.
• Accordingly, spool (11) is pushed up and spool
(7) is pushed to the left by spring (6).
• As a result, port P is closed, so pressure oil from
the control pump does not flow to the actuator.
At the same time, the oil from the actuator flows
from port A2 to port T and is drained to the tank.

• When the signal current flows from the controller
to solenoid (2), solenoid (2) is energized.
• Accordingly, spool (11) is pushed down and the
pressure oil from the control pump flows through
port P to port A1 and spool (7) is pushed to the
right.
• As a result, pressure oil from the control pump
flows from port P to port A2, and then flows to the
actuator.
At the same time, port T is closed, so the oil
does not flow to the tank.
PC750, 800-7 10-107

For swing priority (On left side of machine body)
1. Swing priority solenoid valve
T : To tank
A : To 5-spool control valve
10-108 PC750, 800-7

1. Connector
2. Movable iron core
3. Coil
4. Spool
5. Body
6. Spring
7. Plug
Operation
• The signal current does not flow from the control-
ler, so coil (3) is de-energized.
For this reason, spool (4) is returned to the neu-
tral 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 the signal current flows from the controller
to coil (3), coil (3) is energized and movable iron
core (2) is pushed to the right in the direction of
the arrow.
• For this reason, spool (4) is also pushed to the
right in the direction of the arrow.
As a result, port P is closed, and the pressure oil
from the control pump does not flow to the con-
trol valve.
At the same time, port A and port T are intercon-
nected, and the oil from the control valve is
drained to the tank.
PC750, 800-7 10-109

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
PC750, 750LC, 800-7 STD
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-110 PC750, 800-7

(3)
Unit: mm
Name of Standard Tolerance Standard Clearance

cylinder size Shaft Hole clearance limit
Clearance –0.043 +0.256 0.082 –

Boom 140 0.062
between –0.106 +0.039 0.362 Replace
1
piston rod and bushing
–0.043 +0.256 0.082 –
bushing 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
Clearance –0.090 0 0.115
between
–0.036 +0.025 0.036 –
2 piston rod Arm 115 1.5
–0.090 0 0.115
support shaft
and bushing –0.036 +0.457 0.406 –
Bucket 110 1.5
–0.090 +0.370 0.547 Replace pin,
–0.043 +0.025 0.043 – bushing
Boom 130 1.5
Clearance –0.106 0 0.131
between cylin-
–0.043 +0.025 0.043 –
3 der bottom Arm 130 1.5
–0.106 0 0.131
support shaft
and bushing –0.036 +0.457 0.406 –
Bucket 110 1.5
–0.090 +0.370 0.547
PC750, 800-7 10-111

PC750SE, 800SE-7
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-112 PC750, 800-7

Unit: mm

Clearance –0.043 +0.256 0.082 –

Boom 140 0.062
between –0.106 +0.039 0.362 Replace
1
piston rod and bushing
–0.036 +0.263 0.084 –
bushing Arm 120 0.062
–0.090 +0.048 0.353
–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
Clearance –0.090 0 0.115
between
–0.036 +0.457 0.406 –
2 piston rod Arm 110 1.5
–0.090 +0.370 0.547
support shaft
and bushing –0.043 +0.025 0.043 –
Bucket 140 1.5
–0.106 0 0.131 Replace pin,
–0.043 +0.025 0.043 – bushing
Boom 130 1.5
Clearance –0.106 0 0.131
between cylin-
–0.036 +0.457 0.406 –
3 der bottom Arm 110 1.5
–0.090 +0.370 0.547
support shaft
and bushing –0.043 +0.025 0.043 –
Bucket 140 1.5
–0.106 0 0.131
PC750, 800-7 10-113


PC750-7
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-113-1 PC750, 800-7

(3)
BOTTOM DUMP CYLINDER
Unit: mm

–0.043 +0.256 0.082 –

Boom 140 0.662
Clearance –0.106 +0.039 0.362
between –0.043 +0.256 0.082 – Replace
1 Arm 160 0.662
piston rod and –0.106 +0.039 0.362 bushing
bushing
–0.043 +0.256 0.082 –
Bucket 130 0.662
–0.106 +0.040 0.362
Bottom –0.036 +0.257 0.084 –
90 0.647
dump –0.090 +0.048 0.347
–0.036 +0.025 0.036 –
Boom 115 1.5
–0.090 0 0.115
Clearance –0.043 +0.025 0.043 –
between Arm 140 1.5
–0.106 0 0.131
2 piston rod
support shaft –0.036 0 0.016 –
Bucket 115 1.5
and bushing –0.090 –0.020 0.090
Bottom –0.036 +0.457 0.406 –
90 1.5
dump –0.090 +0.370 0.547 Replace pin,
–0.043 +0.025 0.043 – bushing
Boom 130 1.5
–0.106 0 0.131
Clearance –0.043 +0.025 0.043 –
between cylin- Arm 140 1.5
–0.106 0 0.131
3 der bottom
support shaft –0.036 0 0.016 –
Bucket 115 1.5
and bushing –0.090 –0.020 0.090
Bottom –0.036 +0.457 0.406 –
90 1.5
dump –0.090 +0.370 0.547
PC750, 800-7 10-113-2

(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
PC750-7
PC750LC-7
10-114 PC750, 800-7

Unit: mm

Clearance between bushing size clearance limit
Shaft Hole
1 and mounting pin of boom
and revolving frame –0.043 +0.542 0.485 –
140 1.5
–0.106 +0.442 0.648
Clearance between bushing
–0.043 +0.542 0.485 –
2 and mounting pin of boom 140 1.5
–0.106 +0.442 0.648
and arm
–0.036 +0.351 0.307 –
3 and mounting pin of arm and 115 1.5
–0.090 +0.271 0.441 Replace
link
–0.043 +0.482 0.435 –
–0.106 +0.392 0.588
bucket
–0.036 +0.351 0.307 –
5 and mounting pin of link and 110 1.5
–0.090 +0.271 0.441
link
–0.036 +0.351 0.307 –
–0.090 +0.271 0.441
bucket
7 Bucket clearance 0.5 – 1.0 Adjust shims
PC750, 800-7 10-115

PC750SE-7
PC800, 800SE-7
10-116 PC750, 800-7

Unit: mm

Clearance between bushing size clearance limit
Shaft Hole
1 and mounting pin of boom
and revolving frame –0.043 +0.542 0.485 –
140 1.5
–0.106 +0.442 0.648
–0.043 +0.542 0.485 –
2 and mounting pin of boom 140 1.5
–0.106 +0.442 0.648
and arm
–0.036 +0.351 0.307 –
–0.090 +0.271 0.441
link
Replace
–0.043 +0.482 0.435 –
–0.106 +0.392 0.588
bucket
Clearance –0.036 +0.351 0.307 –
PC800 110 1.5
between –0.090 +0.271 0.441
5 bushing and
mounting pin PC750SE –0.043 +0.397 0.313 –
140 1.5
of link and link PC800SE –0.106 +0.312 0.467

–0.036 +0.351 0.307 –
–0.090 +0.271 0.441
bucket
7 Bucket clearance 0.5 – 1.0 Adjust shims
PC750, 800-7 10-117


PC750-7
10-117-1 PC750, 800-7

(3)
Unit: mm

Clearance between boom- size clearance limit
Shaft Hole
1 revolving frame mounting pin
and bushing –0.043 +0.542 0.485 –
140 1.5
–0.106 +0.442 0.648
Clearance between boom-
–0.043 +0.542 0.485 –
2 arm mounting pin and bush- 140 1.5
–0.106 +0.442 0.648
ing
Clearance between arm- Replace
–0.043 +0.523 0.503 –
3 bucket mounting pin and 140 1.5
–0.106 +0.460 0.629
bushing
Clearance between bucket
–0.036 +0.457 0.406 –
4 cylinder-bucket mounting pin 115 1.5
–0.090 +0.370 0.547
and bushing
Clearance between front
–0.036 +0.344 0.308 –
5 bucket-rear bucket mount- 95 1.5
–0.090 0 0.434
ing pin and bushing
PC750, 800-7 10-117-2

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

1. ARM
10-118 PC750, 800-7

Unit: mm
Model PC750SE-7
PC750-7 PC800-7 PC800SE-7
PC800SE-7
with 3.6 m
with 3.6 m with 4.6 m with 5.6 m with 2.9 m with 3.6 m
heavy-duty
No. arm arm arm short arm arm
arm
1 ø115 ø115 ø115 ø110 ø110 ø110
2 100 100 100 129 129 129
3 531 531 531 531 531 531
4 ø140 ø140 ø140 ø140 ø140 ø140
5 580 620 639 663 750 663
6 397 467 530 329 401 329
7 1,332 1,389 1,328 925 916 925
8 3,578 4,569 5,575 3,585 2,917 3,585
9 3,675 3,688 3,673 4,011 3,580 4,011
10 585 570 585 585 500 585
11 950 950 950 1,035 840 1,035
12 740 740 740 865 640 865
13 756 756 756 765 670 765
14 2,237 2,237 2,237 2,237 2,233 2,237
15 ø115 ø115 ø115 ø115 ø115 ø115
16 519 519 519 519 519 519
17 ø130 ø130 ø130 ø130 ø130 ø130
Arm as
519 519 519 519 519 519
individual part
18
When press-
535 535 535 535 535 535
fitting bushing
Min. 2,380 2,380 2,380 2,590 2,490 2,590

19
Max. 3,990 3,990 3,990 4,410 3,910 4,410
PC750, 800-7 10-119

2. BUCKET
10-120 PC750, 800-7

Unit: mm
Model PC750SE-7
PC750-7 PC800-7 PC800SE-7
PC800SE-7
with 4.0 m3
with 2.8 m3 with 3.1 m3 with 3.4 m3 with 4.0 m3 with 4.3 m3 with 4.5 m3
Light-load
No. bucket bucket bucket bucket bucket bucket
bucket
1 749 749 747 667 667 667 747
2 104 104 164 61 61 61 164
3 98° 98° 102° 95° 95° 95° 102°
4 756 756 765 670 670 670 765
5 2,218 2,218 2,218 2,211 2,211 2,211 2,211
6 292 292 292 315 315 315 315
a ø130 ø130 ø130 ø130 ø130 ø130 ø130

7
b ø115 ø115 ø115 ø115 ø115 ø115 ø115
8 520 520 520 520 520 520 520
9 80.5 80.5 80.5 80.5 80.5 80.5 80.5
10 88.5 88.5 88.5 88.5 88.5 88.5 88.5
11 ø208 ø208 ø238 ø208 ø208 ø208 ø238
12 ø255 ø255 ø255 ø255 ø255 ø255 ø255
13 ø275 ø275 ø275 ø275 ø275 ø275 ø275
14 217 217 253 135 135 135 260
15 175 175 175 181 181 181 181
16 157.5 157.5 157.5 157.5 157.5 157.5 157.5
17 125 125 140 125 125 125 140
18 559.5 559.5 559.5 559.5 559.5 559.5 559.5
19 79 79 79 79 79 79 79
PC750, 800-7 10-121

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
10-122 PC750, 800-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Battery Function
2. Battery relay • The engine can be started and stopped simply by
3. Starting switch using starting switch (3).
4. Fuel control dial • A dial-type engine control is used to control the en-
5. Supply pump gine speed. Engine controller (7) receives the con-
6. Starting motor trol signal from fuel control dial (4), sends a drive
7. Engine controller signal to supply pump (5), and controls the angle of
the governor lever in the fuel injection pump.
PC750, 800-7 10-123

1. Operation of system
Starting engine
• When the starting switch is turned to the START
position, the starting signal flows to the starting
motor, and the starting motor turns to start the
engine.
When this happens, the engine controller
checks the signal from the fuel control dial and
sets the engine speed to the speed set by the
fuel control dial.
Engine speed control

• The fuel control dial sends signal voltages to the
engine controller according to its angle.
The engine controller sends drive signals to the
supply pump according to the signal voltages
received from the fuel control dial and controls
the fuel injection pump to control the engine
speed.
Stopping engine
• When the engine controller detects that the start-
ing switch is at the STOP position, it cuts the sig-
nal to the supply pump drive solenoid to stop the
engine.
10-124 PC750, 800-7

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 bottom of
the monitor panel. A potentiometer is installed
under the knob, and when the knob is turned, it
rotates the potentiometer shaft.
When the shaft rotates, the resistance of the
variable resistor inside the potentiometer
changes, and the desired throttle signal is sent
to the engine controller.
• The hatched area in the graph on the right is the
abnormality detection area and the engine speed
is set at low idling.
PC750, 800-7 10-125

3. Engine controller
10-126 PC750, 800-7

Input and output signals
CN1 [CN-E11] CN2 [CN-E12]

Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
CN1-1 POWER (+24V constant) CN2-1 GND
CN1-2 POWER (+24V constant) CN2-2 NC
CN1-3 Model selection 1 Input CN2-3 NC Input
CN1-4 GND CN2-4 RS232C_1RX Input
CN1-5 NC Input CN2-5 NC
CN1-6 NC Output CN2-6 NC
CN1-7 GND CN2-7 NC Input
CN1-8 GND CN2-8 NC Input
CN1-9 NC Input CN2-9 Sensor 5V power supply 2 Output
CN1-10 GND CN2-10 Fuel control dial Input
CN1-11 NC Input CN2-11 S_NET_SHIELD GND
CN1-12 NC Output CN2-12 CAN_SHIELD
CN1-13 Key switch (ACC) Input CN2-13 NC Output
CN1-14 NC Input CN2-14 RS232C_1TX Output
Engine oil pressure switch (For high CN2-15 G_SHIELD (GND)
CN1-15 Input
pressure) CN2-16 Ne_SHIELD (GND)
CN1-16 Memory clear Input CN2-17 Fuel temperature sensor Input
CN1-17 Model selection 3 Input CN2-18 NC Input
CN1-18 NC Output CN2-19 Sensor 5V power supply 1 Output
CN1-19 Key switch (ACC) Input CN2-20 Boost pressure sensor Input
CN1-20 Starting switch (C) Input Input/
CN2-21 S_NET (+)
Engine oil pressure switch (For low Output
CN1-21 Input
pressure) Input/
CN2-22 CAN0_L
CN1-22 Auto deceleration signal Input Output
CN1-23 Model selection 2 Input CN2-23 NC
CN1-24 NC Output CN2-24 FWE_switch Input
CN2-25 G pulse (–) Input
CN2-26 Ne pulse (–) Input
CN2-27 Water temperature sensor (High) Input
CN2-28 NC Input
CN2-29 Analog GND
CN2-30 NC Input
Input/
CN2-31 S_NET (+)
Output
Input/
CN2-32 CAN0_H
Output
CN2-33 NC
CN2-34 GND (232C_GND)
CN2-35 G pulse (+) Input
CN2-36 Ne pulse (+) Input
CN2-37 Water temperature sensor (Low) Input
CN2-38 NC Input
CN2-39 Analog GND
CN2-40 Common rail pressure sensor Input
PC750, 800-7 10-127

CN3 [CN-E13]
Input/
Pin No. Signal name
Output
CN3-1 Power supply for power
CN3-3 NC
CN3-4 NC
CN3-5 Injector #3 (+) Output
CN3-7 NC Input
CN3-8 Output mode selection 1 (Test mode) Input
CN3-9 Lever neutral flag (Test mode) Input
CN3-10 Engine rotation pulse output Output
CN3-11 Power GND Input
CN3-12 Supply pump 1 (+) Output
CN3-13 Supply pump 2 (+) Output
CN3-15 Injector #3 (–) Output
CN3-17 NC Input
CN3-18 Output mode selection 2 (Test mode) Input
CN3-19 NC Input
CN3-20 Q command output Output
CN3-22 Supply pump 1 (–) Output
CN3-23 Supply pump 2 (–) Output
CN3-27 NC Output
CN3-28 Auto deceleration flag (Test mode) Input
CN3-29 NC Input
CN3-30 GND
CN3-31 Power GND
CN3-32 Power GND
CN3-37 NC Output
CN3-38 Auto deceleration control (Test mode) Input
CN3-39 NC Input
CN3-40 GND
10-128 PC750, 800-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM
MACHINE CONTROL SYSTEM

CONTROL FUNCTIONS
PC750, 800-7 10-129

MACHINE CONTROL SYSTEM DIAGRAM
10-130 PC750, 800-7

1. Auto deceleration system
Function
• If all the control levers are at neutral when wait-
ing for work or waiting for a dump truck, the en-
gine speed is automatically reduced to a
midrange speed to reduce fuel consumption and
noise.
• If any lever is operated, the engine speed returns
immediately to the set speed.
PC750, 800-7 10-131

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 deceleration • If any control lever is operated when the engine
actuation speed (approx. 1400 rpm), and all the speed is at No. 2 deceleration, the engine speed
control levers are returned to neutral, the engine will immediately rise to the speed set by the fuel
speed drops immediately to approx. 100 rpm be- control dial.
low the set speed to the No. 1 deceleration posi-
tion.
• If another 4 seconds passes, the engine speed is
reduced to the No. 2 deceleration position (ap-
prox. 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 1,880 • If any control lever is operated under the condi-
rpm and all the control levers are returned to tion shown at left (after the engine speed drops
neutral, the engine speed drops to approx. 1,880 to approx. 1,880 rpm), the engine speed will im-
rpm after 4 seconds and is kept at that speed un- mediately rise to the speed set by the fuel control
til a lever is operated. dial.
10-132 PC750, 800-7

2. Electronic OLSS function

Pump control system
• Interconnected control of all pumps is carried out

by one TVC valve.
• A mode: Total horsepower control by engine
speed sensing
E mode: Total horsepower control by engine
speed sensing
• Emergency pump drive circuit:
Constant torque control
PC750, 800-7 10-133

1) Control method in each mode

A, E mode
• Matching point in A, E mode: Rated output point
Model PC750-7
Mode PC800-7
338 kW/1,800 rpm

A
{454 HP/1,800 rpm}
291 kW/1,700 rpm
E
{390 HP/1,700 rpm}
• When the load on the pump rises and the pres-

sure rises, the engine speed goes down.
At this time, the pump discharge is reduced and
the engine speed is set about the rated output
point. If the pressure lowers, the pump dis-
charge is increased until the engine speed is set
about the rated output point.
By repeating this control, the engine can always
be used at near the rated output point.
• Compared with the A mode, which provides the
maximum output, the E mode lowers the engine
output to provide matching at a point which gives
better fuel consumption efficiency than the A
mode.
• The A mode uses the CO cancel so it can gener-
ate a greater discharge of oil than in the E mode
at high pressure.
10-134 PC750, 800-7

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

• The cut-off cancel function acts to stop the oper-
ation 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 Travel lever Heavy lift
Function A E ON OFF ON OFF
Cut-off function Cancel Actuated Cancel Actuated Cancel Actuated
PC750, 800-7 10-135

3. Heavy lift function
Outline
• This function increases the boom lifting power by
approx. 10%.
• It can be actuated only when the boom RAISE is
being actuated independently. If the arm IN or
bucket CURL are operated at the same time, the
heavy-lift function is automatically canceled.
10-136 PC750, 800-7

Operation
Lever operation Heavy-lift Main relief
Heavy-lift CO valve Boom lifting
Arm IN or solenoid valve set
switch Boom RAISE switch force
bucket CURL valve pressure
31.4 MPa
OFF Operated — De-energized Actuated Normal
{320 kg/cm2}
34.3 MPa
Neutral Energized Canceled 10% up
{350 kg/cm2}
ON Operated If the arm IN or bucket CURL are operated during

boom RAISE operations, this function is automati-
Operated Normal
cally canceled, and the condition becomes the
same as when the switch is turned OFF.
a Heavy-lift solenoid valve

For details of the structure and function, see SOLENOID VALVE.
a CO valve
For details of the structure and function, see NO. 1 PUMP ASSEMBLY.
a Main relief valve
For details of the structure and function, see L.H. 5-SPOOL CONTROL VALVE.
PC750, 800-7 10-137

4. 2-stage boom pushing force selector function
Outline
• This function switches the pushing force of the
boom. It is aimed to provide both increased dig-
ging efficiency by reducing the digging resist-
ance of the boom, and increased ease of
operation by increasing the thrusting force for ex-
cavation, digging square holes, carrying out twist
turns, or escaping from soft ground.
10-138 PC750, 800-7

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 push-up Machine push-up Safety valve set
Mode Effect
switch solenoid valve pressure
By reducing the boom pushing force, it is

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

Boom pushing LOWER, the ease of operation is improved
33.3 MPa
force De-energized for excavation, digging square holes, car-
{340 kg/cm2}
(high mode) rying out twist turns, or escaping from soft
ground.
a Machine push-up solenoid valve

For details of the structure and function, see SOLENOID VALVE.
a Boom safety valve
For details of the structure and function, see R.H. 4-SPOOL CONTROL VALVE.
PC750, 800-7 10-139

5. Swing control system
Function
• The system is provided with a swing lock and
swing holding brake function.
10-140 PC750, 800-7

Swing lock, swing holding brake function

• The swing lock (manual) can be locked at any a Swing brake solenoid valve
desired position, and the swing lock and swing For details of the structure and function, see
holding brake (automatic) are interconnected SOLENOID VALVE.
with the swing, so they prevent any hydraulic drift a Swing motor
after the swing is stopped. For details of the structure and function, see
SWING MOTOR.
Actuation
Swing lock Swing lock Swing brake
Mode Actuation
switch monitor solenoid valve
When swing and work equipment levers are placed at
neutral, swing brake is applied after approx. 10 sec;
when any swing or work equipment lever is operated,
brake is canceled and swing can be operated freely.
Swing holding See diagram

OFF OFF
brake on right
Swing lock is actuated and swing is held in position.

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

• If any abnormality should occur in the controller, Swing lock ON OFF
and the swing holding brake is not actuated nor- prolix (when controller is (when controller is
mally and the swing cannot be operated, the switch abnormal) normal)
swing lock prolix switch can be operated to can- Swing lock
cel the swing lock and allow the swing to be op- ON OFF ON OFF
switch
erated.
a Even when the swing lock prolix switch is turned Swing
Swing Swing Swing
Swing holding
ON, the swing lock switch stays ON and the lock lock lock
brake brake
swing brake is not canceled. applied canceled applied
applied
a When the swing brake is canceled, the swing
has only a hydraulic brake operated by the
safety valve, so if the swing is stopped on a
slope, there may be hydraulic drift.
PC750, 800-7 10-141

6. Engine automatic warming-up, overheat prevention function, turbo protect function, split
injection function
Function
• If the water temperature is low, this automatically
raises the engine speed to warm up the engine
after it is started. In addition, if the water temper-
ature rises too high during operations, it reduces
the load of the pump to prevent overheating.
• To protect the turbocharger bearing during cold
weather, the engine speed is kept below the
fixed speed when the engine is started. In addi-
tion, to improve the starting ability, a small
amount of fuel is injected two or more times be-
fore the main injection.
10-142 PC750, 800-7

1) Engine automatic warming-up function

• After the engine is started, if the engine coolant
temperature is low, the engine speed is automat-
ically raised to warm up the engine.
2) Engine overheat prevention function

• This function protects the engine by lowering the
pump load and engine speed to prevent over-
heating when the engine coolant temperature
has risen too high.
• This system is actuated at 105°C and above.
PC750, 800-7 10-143

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 during

the above time, the engine speed will not
change. After the set time passes, the operation
moves to the automatic warming up function in
Step 1).
4) Split injection function

To improve the ease of starting in cold weather,
a small amount of fuel is injected two or more
times within the set time after calculating in the
table below before starting the main injection.
As a result, the lower idling speed during this
time becomes slightly higher.
Actuation condition
Split injection time
Water temperature
(sec)
More than 20°C 0
20°C to –30°C 0 – 15
Less than –30°C 15
10-144 PC750, 800-7

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 trav-
el 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 automati-
cally switched to high speed.
Travel speed Travel speed Travel motor

Travel speed Remarks
switch solenoid valve swash plate angle
Low speed Suitable for traveling downhill
Lo De-energized Max.
(max 2.8 km/h) or on rough ground
Max.
Low speed (2.8 km/h) Suitable for use when moving
Hi Energized
High speed (4.2 km/h) long distances
Min
PC750, 800-7 10-145

Outline
• To maintain the drawbar pull when traveling, the
cut-off is canceled and the main relief pressure is
raised from 31.4 MPa {320 kg/cm2} to 34.3 MPa
{350 kg/cm2}.
Operation
Pressure increase Main relief valve Cut-off cancel
CO valve
solenoid valve set pressure solenoid valve
34.3 MPa
When traveling Energized Energized Canceled
{350 kg/cm2}
31.4 MPa
When not traveling De-energized De-energized Actuated
{320 kg/cm2}
10-146 PC750, 800-7

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
Energized Canceled Suitable for compacting or skeleton work
(Contacts closed)
• If the boom is raised, the pilot pressure from the PPC valve is generated in line A. When this happens, the
pressure in line A passes through check valve (2) and pushes the spool of the main valve in the direction of
the arrow. The pilot oil at the left end of the spool passes through line B and the PPC valve, and returns to
the tank. However, when this happens, check valve (4) is being pushed open by the pressure in line A, so it
also allows the oil to pass in the opposite direction. For this reason, the boom can be raised without any delay
in response.
• In this condition, if the boom RAISE operation is stopped, the spool of the main valve moves in the opposite
direction to the arrow and drains the oil from line A. However, the action of check valve (2) means that the
oil must pass through orifice (1). As a result, the spool returns slowly to the neutral position to prevent any
shock.
PC750, 800-7 10-147

9. Straight-travel function
Outline
• When the travel is operated at the same time as • To prevent this, the straight-travel valve is
the boom, arm, or bucket, the pressure oil flow- switched to interconnect the left and right travel
ing to the left and right travel circuits is divided circuits. This ensures that the amount of oil sup-
and sent to the boom, arm, or bucket circuit. plied to the left and right travel motors is equal,
If the oil in one travel circuit is divided off, the so the left and right travel motors both rotate at
amount of oil supplied to the travel motor will be the same speed, and this prevents any travel de-
less than in the travel circuit which is not divided, viation.
so the drop in the supply of oil to the travel
motor will cause the machine to deviate.
10-148 PC750, 800-7

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 circuits
Neutral De-energized Not actuated
independent
Operation
Left and right travel motor circuits
Operated Energized Actuated
assist
PC750, 800-7 10-149

10. Swing priority function

• There is a swing priority mode switch on the
monitor panel. By turning this switch ON/OFF it
is possible to change the matching of the boom
RAISE and swing. This divides the flow to pro-
vide a swing speed which matches the swing an-
gle, thereby enabling the operator to carry out
compound operations easily.
Loading a dump truck on the same ground

Swing priority mode OFF: { Swinging by 90º and loading a dump truck
Swinging by 180º and loading a dump truck
Swing priority mode ON: { Loading a dump truck from a bench
10-150 PC750, 800-7

• 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 mode OFF
ON
OFF (standard) (de-energized)
Swing priority mode ON
OFF
ON (swing priority) (energized)
PC750, 800-7 10-151

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 opera-
tions.
Operation
• If the swing PPC pressure goes above 1.5 MPa {15 kg/cm2} (the control lever is operated approximately half
or more), the swing assurance selector valve is actuated and the swing drive pressure locks the pilot check
valve of the 5-spool valve arm and bucket throttle valves.
• In this condition, the circuits are in parallel, so the oil from the 5-spool valve flowing to the arm or bucket is
throttled by the throttle valve, so the swing drive pressure rises. In this way, the swing drive is assured.
10-152 PC750, 800-7

12. Components of system
1) Engine speed sensor
1. Wire Function
2. Magnet • The engine speed sensor is installed to the ring
3. Terminal gear portion of the engine flywheel. It counts elec-
4. Housing trically the number of gear teeth that pass in front of
5. Connector the sensor, and sends the results to the engine con-
troller and pump controller.
• This detection is carried out by a magnet, and an
electric current is generated every time the gear
tooth passes in front of the magnet.
2) PPC hydraulic switch

1. Plug
2. Switch
3. Connector
Specifications
Composition of points: N.O. points
Actuation (ON) pressure:
0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2}
Reset (OFF) pressure:
0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm2}
Function
• There are 12 switches installed to
the PPC block. The operating condi-
tion of each actuator is detected
from the PPC pressure, and this is
sent to the engine controller and
pump controller.
PC750, 800-7 10-153

3) TVC prolix resistor
1. Resistor
2. Connector
Specification Function
Resistance: 20 z • This resistor acts to allow a suitable current to
flow to the TVC solenoid when the TVC prolix
switch is ON.
• No current flows when the TVC prolix switch is
OFF.
4) Fuel control dial, engine controller

a See ENGINE CONTROL.
5) Monitor panel
a See MONITOR SYSTEM.
6) TVC valve
a See HYDRAULIC PUMP.
10-154 PC750, 800-7

7) Pump controller
PC750, 800-7 10-155

CN1 [CN-C01] CN2 [CN-C02]

Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
CN1-1 NC Input CN2-1 NC Output
CN1-2 R pump pressure sensor Input CN2-2 Swing prolix switch Input
CN1-3 NC Input CN2-3 NC Input
CN1-4 NC CN2-4 RS232C-R × D Input
CN1-5 Auto grease controller trouble Input CN2-5 Overload sensor (ON/OFF) Input
CN1-7 NC Input CN2-7 Model selection 4 (ATT) Input
CN1-8 F pump pressure sensor Input CN2-8 NC Output
CN1-10 GND (SIG) CN2-10 NC Input
CN1-11 (Knob switch) Input CN2-11 NC Output
CN1-12 NC Input CN2-12 CAN_SH
CN1-14 NC Input CN2-14 RS232C-T × D Output
CN1-16 NC Output CN2-16 Left travel pressure switch Input
CN1-17 Key switch (Terminal C) Input CN2-17 Model selection 3 Input
CN1-19 NC Input CN2-19 Auto deceleration Output
CN1-21 NC Input/
CN2-21 S_NET
CN1-22 Sensor power supply (+5V) Output Output
CN1-23 Key switch (Terminal Acc) Input Input/
CN2-22 CAN0_L
CN1-24 Stop light switch Input Output
Input/
CN2-23 NC
Output
CN2-24 Boot program switch Input
CN2-25 Horn switch Input
CN2-26 NC Input
CN2-27 Model selection 2 Input
CN2-28 NC Input
CN2-29 NC
CN2-30 NC Input
CN2-31 GND (S_NET_GND)
Input/
CN2-32 CAN0_H
Output
Input/
CN2-33 NC
Output
CN2-34 GND (RS232C)
CN2-35 Service valve pressure switch Input
CN2-36 NC Input
CN2-37 Model selection 1 Input
CN2-38 Swing lock switch Input
CN2-39 Engine speed sensor (GND)
CN2-40 Engine speed sensor Input
10-156 PC750, 800-7

CN3 [CN-C03]
Input/
Pin No. Signal name
Output
CN3-1 VB (Controller PWR) Input
CN3-2 VIS (Solenoid PWR) Input
CN3-3 TVC solenoid (–) Input
CN3-4 Battery relay drive Output
CN3-5 Step light power holding relay Output
CN3-6 NC Output
CN3-7 Straight travel solenoid Output
CN3-8 Travel alarm Output
CN3-9 Bucket CURL pressure switch Input
CN3-10 Boom RAISE pressure switch Input
CN3-12 VIS (Solenoid PWR) Input
CN3-13 NC Input
CN3-15 Step light drive relay Output
CN3-16 TVC solenoid (+) Output
CN3-17 CO cancel solenoid Output
CN3-18 NC Output
CN3-19 Bucket DUMP pressure switch Input
CN3-20 Boom LOWER pressure switch Input
CN3-21 GND (Controller GND) Input
CN3-22 NC Input
CN3-23 NC Input
CN3-25 Flash light driver relay Output
CN3-26 NC Output
CN3-27 Travel Hi/Lo selector solenoid Output
CN3-28 2-stage relief solenoid Output
CN3-29 Swing pressure switch Input
CN3-30 Arm IN pressure switch Input
CN3-34 NC
CN3-35 NC Output
CN3-36 NC Output
CN3-37 Swing holding brake solenoid Output
CN3-38 Swing priority solenoid Output
CN3-39 Right travel pressure switch Input
CN3-40 Arm OUT pressure switch Input
PC750, 800-7 10-157

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
• The monitor system monitors the condition of the

machine with sensors installed on various parts
of the machine. It processes and immediately
displays the obtained information on the panel
notifying the operator of the condition of the ma-
chine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when the
machine has troubles
2. Gauge section to display the condition con-
stantly (Coolant temperature, hydraulic oil
temperature, fuel level, etc.)
• The monitor panel also has various mode selec-
tor switches and functions to operate the ma-
chine control system.
10-158 PC750, 800-7

1. Monitor panel
Outline
• The monitor panel has the functions to display
various items and the functions to select modes
and electric parts.
The monitor panel has a CPU (Central Process-
ing Unit) in it to process, display, and output the
information.
The monitor display unit consists of LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
PC750, 800-7 10-159

CN1 CN3
Pin Input/ Pin Input/
Signal name Signal name
No. output No. output
1 Key switch (Battery) Input 1 NC Input
2 Key switch (Battery) Input 2 NC Input
3 Washer motor output Output 3 NC Input
4 Key switch (Terminal C) Input 4 NC Input
5 Wiper contact W (Lower wiper contact P) Input 5 NC Input
6 GND 6 NC Input
7 GND 7 NC Input
8 VB + (24 V) Input 8 NC Input
9 Wiper motor (+) <Upper wiper motor (+)> Output Input/
9 NC
10 Wiper motor (–) <Lower wiper motor (–)> Output output
11 NC Input Input/
10 NC
12 Wiper contact P (Upper wiper contact P) Input output
11 NC Input
12 NC Input
CN2 13 NC
Pin Input/ 14 CAN (Shield) Input
Signal name
No. output 15 CAN (+) Input
1 NC Input 16 CAN (–) Input
2 Fuel Input
3 Radiator water level Input
4 NC Input
5 Air cleaner clogging sensor Input
6 NC Input
7 NC Input
8 Engine oil level sensor Input
Input/
9 Network (S-NET signal)
output
Input/
10 Network (S-NET signal)
output
11 Charge level Input
12 Hydraulic oil temperature (Analog) Input
13 GND (For analog signal)
14 Personal code relay (Lo) Input
15 Window limit switch <Lower wiper switch> Input
16 Buzzer cancel Input
17 Swing lock Input
18 Preheating Input
19 Light switch Input
20 Network (S-NET GND)
10-160 PC750, 800-7

MONITOR CONTROL, DISPLAY PORTION
MONITOR PORTION
1. Wiper motor 11. Fuel level monitor

2. Preheating monitor 12. Hydraulic oil temperature monitor
3. Swing lock monitor 13. Auto-deceleration monitor
4. Engine water temperature monitor 14. Radiator water level caution
5. Hydraulic oil temperature gauge 15. Battery charge caution
6. Engine water temperature gauge 16. Engine oil pressure caution
7. Working mode monitor 17. Engine oil level caution
8. Service meter 18. Air cleaner clogging
9. Travel speed monitor 19. Maintenance time warning caution
10. Fuel gauge
PC750, 800-7 10-161

(3)
MONITOR ITEMS AND DISPLAY

Symbol Display item Display method
Swing holding brake

Swing lock switch Swing lock monitor
release switch
OFF OFF OFF
Swing lock
ON OFF ON
OFF ON Flashes
ON ON ON
Continuous set time Preheating monitor status

Up to 30 sec. ON
Preheating
From 30 sec. to 40 sec. Flashes
More than 40 sec. OFF
Engine water
temperature
Hydraulic oil
See gauge display on the next page
temperature
Fuel level
10-162 PC750, 800-7

Gauge Range Temperature, volume Indicator Buzzer sound

A1 105 Red
A2 102 Red
Engine water A3 100 Green

temperature (°C) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
Hydraulic oil tempera- B3 100 Green

ture (°C) B4 80 Green
B5 40 Green
B6 20 White
C1 524 Green
C2 382 Green
C3 249 Green
Fuel level (l)
C4 138 Green
C5 101 Green
C6 84 Red
PC750, 800-7 10-163

Checks before starting (caution lamps all light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil
temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are dis-
played.
Check before starting When engine is When engine is

Symbol Display item
item stopped running
When abnormal,
Engine oil pressure q — lights up and buzzer
sounds
Lights up when
Battery charge q —
abnormal
When abnormal,
Lights up when
Radiator water level q lights up and buzzer
abnormal
sounds
Lights up when
Engine oil level q —
abnormal
Lights up when
Air cleaner clogging q —
abnormal
Lights up when there is a warning. Lights up for

Maintenance only 30 sec. after key is turned ON, then goes
out.
The problems that have occurred are displayed in order from the left.
When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is dis-
played.
Condition of hydraulic oil Color of symbol

Low temperature (below B6 or equivalent) Black on white background
Normal (B6 – B2) No display
High temperature (above B2) White on red letters
10-164 PC750, 800-7

(3)
Display category Symbol Display item Display range Display method
ON INT OFF
Wiper Displays set condition
Working mode Displays set mode
Monitor
Travel speed Displays set speed
Auto-decelera- Displays actuation

ON OFF
tion status
Service meter Lights up when service

Service meter When service meter is working
indicator meter is working
PC750, 800-7 10-165

SWITCHES
1. Working mode selector switch

2. Display brightness, contrast adjustment switch
3. Control switch
4. Window washer switch
5. Wiper switch
6. Maintenance switch
7. Travel speed selector switch
8. Auto-deceleration switch
10-166 PC750, 800-7

• Working mode selector switch

The condition of the machine changes accord- Switch that is Working mode status
Display
ing to the switch that is pressed (Shown in the pressed after setting
figure at right). It is possible to check the condi-
[A] A A mode (default)
tion on the working mode monitor display. The
relationship between each working mode and [E] E E mode
the monitor display is shown in the table on the
right. Heavy-lift mode
• Maintenance switch
Check the condition of the maintenance items.
(For details, see MAINTENANCE FUNCTION.) Swing priority mode
• Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON/OFF.
Use the auto-deceleration monitor display to
check the present condition.
When the working mode switch is operated to
switch the working mode, it is automatically set
to ON.
• Travel speed selector switch Display Setting

Each time the travel speed selector switch is
Crawler symbol + Lo Low speed (default)
pressed, the travel speed changes.
Lo o Hi o Lo …… Crawler symbol + Hi High speed
Use the travel speed monitor display to check
the present condition.
The relationship between the set speed and the
monitor display in the table on the right.
• Wiper switch Wiper actuation

Display Setting
Each time the wiper switch is pressed, the wiper status
setting changes OFF o INT o ON o OFF o
Stowing stopped or
…… None OFF
now stowing
Use the wiper monitor display to check the
present condition. Wiper symbol + INT INT Intermittent actuation
The relationship between the wiper setting and Wiper symbol + ON ON Continuous actuation
the monitor display is as shown in the table on
the right.
• Window washer switch

While the switch is being pressed, window
washer liquid is sprayed out. There is a time
delay before the wiper starts.
• Control switch
This is used for control when using the mainte-
nance function or select function.
(For details, see each function.)
• Display brightness, contrast adjustment switch

Use this switch when adjusting the display
brightness and contrast.
(For details, see each function.)
PC750, 800-7 10-167

MAINTENANCE FUNCTION
When the maintenance time for replacement,

inspection, or filling has approached for the 10 main-
tenance items, press maintenance switch (1) and
the caution display (yellow or red) appears on the
monitor display for 30 seconds after the key is
turned ON to remind the operator to carry out lubri-
cation maintenance.
a Maintenance items
Replacement
No. Item
interval (hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel filter 500
04 Hydraulic filter 1,000
05 Hydraulic tank breather 1,000
06 Corrosion resistor 1,000
07 Damper case oil 1,000
08 Final case oil 2,000
09 Machinery case oil 1,000
10 Hydraulic oil 5,000
11 Pilot filter 500
12 Drain filter 500
a The above replacement intervals are set for

each item, and the time remaining to mainte-
nance is reduced as the machine is operated.
The content of the caution display differs
according to the ramaining time. The relation-
ship is as shown in the table below.
Display Condition
Remaining time for mainte-
None nance for all items is more
than 30 hours
There is one or more items
Notice display (black sym-
with less than 30 hours
bol displayed on yellow
remaining time for mainte-
background)
nance
There is one or more items
Warning display (wiper
with less than 0 hours
symbol displayed on red
remaining time for mainte-
background)
nance
10-168 PC750, 800-7

METHOD OF CHECKING STATUS
MAINTENANCE ITEMS
a Operate as follows when on the operator

screen.
1. Press maintenance switch (1) and switch to the
maintenance list display screen.
a The maintencance items are displayed as
symbols on the screen.
2. Press control switch (2), or use the 10-key pad
to input the number (01 – 10, 30, 31) of the
maintenance item to select the item.
a The cursor moves and the item is highlight-
ed.
a The display method is the same as de-
scribed on the previous page (relationship
between remaining time and caution dis-
play). If the remaining time is less than 30
hours, the item is displayed in yellow, and if
it is less than 0 hours, it is displayed in red.
MAINTENANCE OPERATION
1. After completing the selection, press input con-

firmation switch (3).
The screen will change to the maintenance
reset screen.
2. Use the maintenance reset screen to check the
content, and if there is any problem, press input
confirmation switch (3) to move to the check
screen.
If the wrong item is selected, press return switch
(4) to return to the maintenance list screen.
3. Check the content on the check screen, and if
there is no problem, press input confirmation
switch (3) to reset the maintenance time.
After the reset is completed, the screen returns
to the maintenance list display screen. To check
the remaining time, or if the wrong item is
selected, press return switch (4) to return to the
maintenance list screen.
a The check screen shows the symbol for the
maintenance item and the set time in large
letters.
a The background color of the symbol for the
item where the maintenance item was reset
is the same as the background of the screen,
so it is possible to check that it has been re-
set.
PC750, 800-7 10-169

BRIGHTNESS, CONTRAST ADJUSTMENT

FUNCTION
This function is used to adjust the brightness and

contrast of the display.
Adjustment method
a Operate as follows when on the operator

screen.
1. Press display brightness/contrast adjustment
switch (1) and switch to the adjustment screen.
a Relationship between menu symbol and con-

tent.
No. Symbol Content
00 Return mark Return
01 Contrast
02 Brightness
2. Press control switch (2), or use the 10-key pad

to input the number (00 – 02) to select either
contrast or brightness.
After completing the selection, press input con-
firmation switch (3) and return to the adjustment
screen.
Then press return switch (4) or use the 10-key
pad to set to [00] and press input confirmation
switch (3) to return to the normal screen.
3. Press control switch (2) and adjust the bright-
ness and contrast as desired.
Control switch Actuation
Flow level bar graph

extends to the right
Flow level bar graph

retracts to the left
10-170 PC750, 800-7

(3)
SERVICE METER CHECK FUNCTION
• When the starting switch is at the OFF position,

keep return switch (1) and control switch (2) of
the monitor pressed at the same time, and the
service meter is shown on the display.
• This display is shown only while the two switches
are being pressed. When the switches are re-
leased, the display goes out.
Note that it takes 3 – 5 seconds after the
switches are pressed for the service meter dis-
play to appear.
DISPLAY LCD CHECK FUNCTION
• On the password input screen or on the normal

screen, if monitor return switch (1) and working
mode (A) switch are kept pressed at the same
time, all the LCD display will light up and the
whole screen will become white, so the display
can be checked.
If any part of the display is black, the LCD is bro-
ken.
USER CODE DISPLAY FUNCTION
• If there is any problem in operating the machine,

the user code is displayed on the monitor to ad-
vise the operator of the steps to take.
This code display appears on the operator
screen.
• On the operator screen, the user code is dis-
played on the portion for the hydraulic oil temper-
ature gauge.
• If more than one user code is generated at the

same time, the user codes are displayed in turn
for 2 seconds each to display all the user codes.
PC750, 800-7 10-171

• While the user code is being displayed, if the in-

put cnfirmation switch is pressed, the service
code and failure code can be displayed.
• If there is more than one service code or failure

code, the display switchs every 2 seconds and
displays all the service codes/failure codes that
caused the user code to be displayed.
Even if service codes/failure codes have
occurred, if they did not cause the user code to
be displayed, this function does not display
them.
• If the telephone number has been set using the

telephone number input on the service menu, it
is possible to switch on the service code/failure
code and display the telephone symbol and tele-
phone number.
For details of inputting and setting the telephone
number, see SPECIAL FUNCTIONS OF MONI-
TOR PANEL in the TESTING AND ADJUSTING
section.
10-172 PC750, 800-7

(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS
SENSORS
• The signals from the sensors are input directly to The contact type sensors are always connected
the engine controller and the pump controller at one end to the chassis GND.
monitor.
Name of sensor Type of sensor When normal When abnormal Input controller
Coolant level Contact type ON (closed) OFF (open) Monitor
Engine oil level Contact type ON (closed) OFF (open) Monitor
Engine oil pressure Contact type ON (closed) OFF (open) Engine controller
Coolant temperature Resistance type — — Engine controller
Fuel level Resistance type — — Monitor
Air cleaner clogging Contact type OFF (open) ON (closed) Monitor
Hydraulic oil temperature Contact type — — Monitor
Main pump oil pressure Analog — — Pump controller
Coolant level sensor
1. Sub-tank
2. Float
3. Sensor
4. Connector
PC750, 800-7 10-173

Engine 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
10-174 PC750, 800-7

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, 800-7 10-175

Main pump oil pressure sensor (0 – 49.0 MPa {0 – 500 kg/cm2})
1. Sensor
2. Connector
10-176 PC750, 800-7

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-2

STANDARD VALUE TABLE FOR CHASSIS .................................................................................................. 20-3
TESTING AND ADJUSTING ...................................................................................................................... 20-101
TROUBLESHOOTING ................................................................................................................................ 20-201
PC750, 800-7 20-1

(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

PC750, SE, LC-7
Machine model
PC800, SE-7
Engine SAA6D140E-3
Item Measurement condition Unit Standard value Permissible value

High idling 1,980 ± 50 1,980 ± 50
Engine speed Low idling rpm 825 ± 25 825 ± 25
Rated speed 1,800 1,800

kPa
Intake air pressure At rated output Min 147 {Min. 1,100} 117 {880}
{mmHg}
Exhaust gas All speed range
°C Max. 700 Max. 750
pressure (intake air temp: 20°C)
At sudden acceleration Max. 4.0 7.0
Bosch
Exhaust gas color
index
At high idling Max. 1.0 2.0
Intake valve 0.35 —
Valve clearance
mm
(normal temperature)
Exhaust valve 0.57 —
Compression Oil temperature: 40 – 60°C MPa
Min. 4.1 {Min. 42} 2.8 {29}
pressure (Engine speed: 160 – 200 rpm) {kg/cm2}
(Coolant temperature:
kPa
Blow-by pressure within operating range) Max. 1.96 {Max. 200} 3.9 {400}
{mmH2O}
At rated output
(Coolant temperature:
within operating range)
At high idling (SAE30) 0.34 – 0.54 {3.5 – 5.5} 0.21 {2.1}

MPa
Oil pressure
At high idling (SAE10W) {kg/cm2} 0.29 – 0.49 {3.0 – 5.5} 0.18 {1.8}
At low idling (SAE30) Min. 0.12 {Min. 1.2} 0.08 {0.8}
At low idling (SAE10W) Min. 0.1 {Min. 1.0} 0.07 {0.7}

Oil temperature All speed range (inside oil pan) °C 90 – 110 120
Deflection when pressed with fin-
Alternator belt tension mm 10 – 15 10 – 15
ger force of approx. 58.8 N {6 kg}
Air conditioner
Deflection when pressed with fin-
compressor belt mm 10 – 15 10 – 15
ger force of approx. 58.8 N {6 kg}
tension
20-2 PC750, 800-7

(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

PC750, SE, LC-7
Applicable model
PC800, SE-7
Cate- Standard value for
Item Measurement conditions Unit Service limit value
gory new machine
• Engine water temperature:
Within operating range
• Hydraulic oil temperature:
All pumps at relief Within operating range Min. 1,700 Min. 1,700
• Engine at high idling
• Working mode: A
• Boom up relief
• Engine water temperature:
Engine speed

Heavy lift ON • Hydraulic oil temperature:
+ Within operating range rpm Min. 1,700 Min. 1,700
All pumps at relief • Engine at high idling
• Working mode: A & heavy lift
• Boom up relief
High idling-cut ON • Auto-deceleration switch OFF 1,880 ± 100 1,880 ± 100
• All control levers at neutral
Auto-deceleration
• Auto-deceleration switch ON 1,400 ± 100 1,400 ± 100
actuated
• All control levers at neutral
Boom Lo control valve
Boom Hi control valve
Arm Lo control valve
Spool stroke
Arm Hi control valve

• Stroke of each side 16 ± 0.5 16 ± 0.5
Bucket Lo control valve
Bucket Hi control valve
Swing control valve
Travel control valve
N o Raise,
Boom control lever mm 85 ± 10 85 ± 10
Lower
Arm control lever • Center of N o In, Out 85 ± 10 85 ± 10

Travel of control levers
lever knob
• Read max.
Bucket control lever value to end N o Curl, Dump 85 ± 10 85 ± 10
of travel
Swing control lever (Exclude play N o R.H., L.H. 85 ± 10 85 ± 10
at neutral.)
• Engine N o F, R
Travel control lever stopped 115 ± 12 115 ± 12
(L.H., R.H.)
Work equipment,
Play of control levers Max. 10 Max. 15
swing, travel
PC750, 800-7 20-3

(1)
PC750, SE, LC-7

Applicable model
PC800, SE-7
gory new machine
15.7 ± 4.9 15.7 ± 4.9
Boom control lever
{1.6 ± 0.5} {1.6 ± 0.5}
• Hydraulic oil temperature: 15.7 ± 4.9 15.7 ± 4.9
Arm control lever
Operating effort of control levers
Within operating range {1.6 ± 0.5} {1.6 ± 0.5}

• Center of lever knob 12.7 ± 3.9 12.7 ± 3.9
Bucket control lever • Measure max. value to end of {1.3 ± 0.4} {1.3 ± 0.4}
travel N {kg}
12.7 ± 3.9 12.7 ± 3.9
Swing control lever
{1.3 ± 0.4} {1.3 ± 0.4}
24.5 ± 5.9 Max. 39.2
Lever
Travel control lever, {2.5 ± 0.6} {Max. 4.0}
pedal 74.5 ± 18.6 Max. 107.6
Pedal
{7.6 ± 1.9} {Max. 11}
31.4 ± 1.0 31.4 +1.0
–2.0
Normal +10
{320 ± 10} {320 –20 }
RAISE
33.8 ± 1.0 33.8 +1.0

–2.0
At heavy lift +10
{345 ± 10} {345 –20 }
Boom relief pressure
• Hydraulic oil 18.6 ± 1.9 18.6 ± 1.9
temperature: Normal
LOWER
{190 ± 20} {190 ± 20}

Within operat-
ing range At machine 31.4 ± 1.0 31.4 +1.0
–2.0
• Engine at high push-up +10
idling {320 ± 10} {320 –20 }
• Working 31.4 ± 1.0 31.4 +1.0
mode: A –2.0
Arm relief pressure +10
• Pump outlet {320 ± 10} {320 –20 }
pressure
31.4 ± 1.0 31.4 +1.0
when mea- –2.0
Curl +10
sured circuit is {320 ± 10} {320 –20 }
Hydraulic pressure
Bucket relief pressure relieved

32.4 ± 1.0 32.4 +1.0
• Relieve either Dump –2.0
travel circuit. MPa +10
{330 ± 10} {330 –20 }
{kg/cm2}
28.4 +2.5 28.4 +2.5
Swing relief pressure –0.5 –0.5
{290 +25 } {290 +25 }
–25 –25
34.3 ± 1.0 34.3 +1.0
–2.0
Travel relief pressure +10
{350 ± 10} {350 –20 }
• Hydraulic oil temperature: 3.33 +0.49 3.33 +0.49
–0 –0
Control pressure Within operating range +5 +5
• Engine at high idling {350 0 } {350 0 }
All control
2.21 ± 0.2 Min. 1.76
• Hydraulic oil levers at
{22.5 ± 2} {Min. 18}
temperature: neutral
Within operat-
TVC valve output ing range Boom RAISE 1.23 ± 0.2 1.18 ± 0.2
pressure • Engine at high relief (Normal) {12.5 ± 2} {12 ± 2}
idling
• Working Heavy lift ON +
1.19 ± 0.2 1.14 ± 0.2
mode: A Boom RAISE
{12.1 ± 2} {11.6 ± 2}
relief
20-4 PC750, 800-7

(1)
PC750, SE, LC-7

Applicable model
PC800, SE-7
gory new machine
• Hydraulic oil All control

Max. 0.4 Max. 0.55
temperature: levers at
{Max. 4} {Max. 5.5}
Within operat- neutral
ing range
• Engine at high Boom RAISE 1.23 ± 0.2 1.18 ± 0.2
idling relief (Normal) {12.5 ± 2} {12 ± 2}
CO-NC valve output
• Working
pressure Track running
mode: A Min. 1.67 Min. 1.67
• When track idle (Lever at
{Min. 17} {Min. 17}
runs idle, stroke end)
measure oil Heavy lift ON +
pressure on 1.19 ± 0.2 1.14 ± 0.2
Boom RAISE
idle side. {12.1 ± 2} {11.6 ± 2}
relief
Hydraulic pressure
• Hydraulic oil
All control Min. 1.14 Min. 1.14
temperature: MPa
levers at neutral {Min. 11.6} {Min. 11.6}
Within operat- {kg/cm2}
Jet sensor output ing range
negative pressure • Engine at high Track running
idling Max. 0.15 Max. 0.15
idle (Lever at
• Working {Max. 1.5} {Max. 1.5}
stroke end)
mode: A
PPC valve output Within operating range
pressure • Engine at high idling
• Control lever at stroke end
Max. 2.0 Max. 2.9
Oil pressure drop • Difference between relief pres-
{Max. 20} {Max. 30}
sure at high idling and that at
low idling
Overrun when stopping • Hydraulic oil temperature:

Swing
deg. Max. 60 Max. 80

swing Within operating range (mm) (Max. 1,035) (Max. 1,380)
• Bucket: No load
• Working mode: A
• Stop after swinging one turn
and measure distance that
swing circle moves
PC750, 800-7 20-5

(1)
PC750, SE, LC-7

Applicable model
PC800, SE-7
gory new machine
90° 4.4 ± 0.5 Max. 5.3
• Hydraulic oil tempera-

Time taken to start ture: Within operating sec.
swing range
• Bucket: No load
180° 6.8 ± 0.7 Max. 8.2
• Working mode: A
• Time taken to swing 90°
and 180° from starting
position
Time taken to swing • Hydraulic oil temperature: sec. 41 – 47 Max. 50

• Bucket: No load
• Working mode: A
Swing
• Swing one turn, then measure

time taken to swing next 5 turns

Hydraulic drift of swing • Engine stopped mm 0 0
• Set machine on 15° slope, and
set upper structure at 90° to the
side.
• Make match marks on inner
race and outer race of circle.
• Measure distance that match
marks move apart after 5 min-
utes.
Leakage from swing • Engine at high idling
l/min Max. 5 Max. 10
motor • Swing lock switch: ON
• Leakage in 1 minute during
swing relief
20-6 PC750, 800-7

(1)
PC750, SE, LC-7

Applicable model
PC800, SE-7
gory new machine
74 – 90 74 –90
Lo (PC750LC-7: (PC750LC-7:
80 – 98) 80 – 98)

Travel speed ture: Within operating sec.
(Idle travel) range
• Working mode: A
48 – 59 48 – 59
• Raise track on one side
at a time, rotate one turn, Hi (PC750LC-7: (PC750LC-7:
52 – 64) 52 – 64)
then measure time taken
for next 5 turns with no
load.
Lo 22 – 29 22 – 29

Travel speed ture: Within operating sec.
(Actual travel) range
Travel
• Working mode: A
• On flat place
• Run up for at least 10 m, Hi 15 – 19 15 – 19
and measure time taken
to travel next 20 m on flat
ground.

• Working mode: A
Travel deviation • Travel speed: Lo mm Max. 200 Max. 220
• On hard and flat place
• Measure travel deviation (x) in
travel of 20 m after running up
10 m.
PC750, 800-7 20-7

(1)
PC750, SE, LC-7

Applicable model
PC800, SE-7
gory new machine

Hydraulic drift of travel Within operating range mm 0 0
• Engine stopped
• Stop machine on 12° slope with
Travel
sprocket at uphill end of

machine.
• Measure the distance the
machine moves in 5 minutes.
Leakage of travel • Engine at high idling
l/min Max. 20 Max. 40
motor • Travel: Lock sprocket.
• Measure leakage in 1 minute
during travel relief.
Total work equip-

ment Max. 1,400 Max. 1,800
(hydraulic drift at (Max. 900) (Max. 1,000)
tip of bucket teeth)
Hydraulic drift of work equipment

Boom cylinder
Within operating range 60 Max. 90
(amout of retrac-
• On level and flat place (35) (Max. 50)
Work equipment
tion of cylinder)
• Work equipment: In above mea-
suring posture with rated load
mm
Standard (LC): 49 kN {5,000 kg}
SE: 64 kN {6,500 kg}
Arm cylinder • Engine: Stopped 165 Max. 250
(amount of exten- • Work equipment control lever: (70) (Max. 105)
sion of cylinder) Neutral
• Start measuring just after set-
ting machine and measure
every 5 minutes for 15 minutes.
Bucket cylinder • Figures in ( ) are for empty work
50 Max. 75
(amount of retrac- equipment.
(15) (Max. 25)
tion of cylinder)
20-8 PC750, 800-7

(1)
PC750, SE, LC-7

Applicable model
PC800, SE-7
gory new machine
PC750 (LC): 5.3 ± 0.5 PC750 (LC): Max. 6.7
RAISE
PC750SE: 5.6 ± 0.6 PC750SE: Max. 7.2
PC800: 5.3 ± 0.5 PC800: Max. 6.7
PC800SE: 5.6 ± 0.6 PC800SE: Max. 7.2
Boom speed • Engine: High idling
• Working mode: A
• Measure time taken to
PC750 (LC): 4.3 ± 0.4 PC750 (LC): Max. 5.1
LOWER
move bucket between
PC750SE: 4.4 ± 0.4 PC750SE: Max. 5.2
RAISE stroke end and
PC800: 4.2 ± 0.4 PC800: Max. 5.0
ground touch point of
PC800SE: 4.4 ± 0.4 PC800SE: Max. 5.2
bucket (including operating
time of cylinder cushion).
PC750 (LC): 4.7 ± 0.5 PC750 (LC): Max. 5.9

PC750SE: 5.4 ± 0.5 PC750SE: Max. 6.6
IN
PC800: 5.4 ± 0.5 PC800: Max. 6.6

Work equipment speed
PC800SE: 5.4 ± 0.5 PC800SE: Max. 6.6

Work equipment
Arm speed • Hydraulic oil temperature:

Within operating range sec.
• Engine: High idling
• Working mode: A PC750 (LC): 3.6 ± 0.3 PC750 (LC): Max. 4.6
• Measure time taken to PC750SE: 4.1 ± 0.4 PC750SE: Max. 5.1
OUT
move arm between OUT PC800: 4.1 ± 0.4 PC800: Max. 5.1
stroke end and IN stroke PC800SE: 4.1 ± 0.4 PC800SE: Max. 5.1
end (including operating
time of cylinder cushion).
PC750 (LC): 3.3 ± 0.3 PC750 (LC): Max. 3.9

CURL
PC750SE: 4.6 ± 0.5 PC750SE: Max. 5.6

PC800: 3.6 ± 0.4 PC800: Max. 4.4
PC800SE: 4.6 ± 0.5 PC800SE: Max. 5.6

Bucket speed Within operating range
• Working mode: A
• Measure time taken to PC750 (LC): 3.5 ± 0.3 PC750 (LC): Max. 4.1
DUMP
move bucket between PC750SE: 4.2 ± 0.4 PC750SE: Max. 5.0

DUMP stroke end and PC800: 3.7 ± 0.3 PC800: Max. 4.3
CURL stroke end (including PC800SE: 4.2 ± 0.4 PC800SE: Max. 5.0
operating time of cylinder
cushion).
PC750, 800-7 20-9

(1)
PC750, SE, LC-7

Applicable model
PC800, SE-7
gory new machine

Boom time lag Within operating range Max. 6 Max. 6
• Engine: Low idling
• Working mode: A
• Lower boom from RAISE stroke
end and measure time taken to
lift up front side of machine after
bucket touches ground.
Time lag

Arm time lag sec. Max. 5 Max. 5
Work equipment

• Working mode: A
• Move in arm from OUT stroke
start moving arm again after it is
stopped.

Bucket time lag Max. 4 Max. 4
• Working mode: A
• Curl bucket from DUMP stroke
start moving bucket again after
it is stopped.

Cylinder Within operating range Max. 5 Max. 20
Oil leakage

• Relieve cylinder to be mea- cc/min
Center swivel joint sured or travel circuit and mea- Max. 10 Max. 100
sure leakage in 1 minute.
performance
Pump
Hydraulic pump
• See following page. l/min See following page.
discharge amount
20-10 PC750, 800-7

(1)
Cate-
Discharge amount of one hydraulic pump
gory
Performance of hydraulic pump
• TVC current : 400 mA

• Pump speed: At 2,400 rpm (Engine rated speed at 1,800 rpm)
Test pump Discharge Standard value Judgement

Average
discharge pressure of for discharge standard lower
Check point pressure
pressure other pump amount Q limit Q
(MPa {kg/cm2})
(MPa {kg/cm2} (MPa {kg/cm2}) (l/min) (l/min)
P1 + P2
As desired P1 P2 See graph See graph
2
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when
measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the speci-
fied speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of mea-
surement, and use them as a base for calculating the pump discharge amount at the specified speed.
PC750, 800-7 20-11

(1)
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING........................................................... 20-102
MEASURING ENGINE SPEED .................................................................................................................. 20-104
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) ................................................................ 20-105
MEASUREMENT OF EXHAUST GAS TEMPERATURE............................................................................ 20-106
MEASUREMENT OF EXHAUST GAS COLOR.......................................................................................... 20-107
ADJUSTING VALVE CLEARANCE............................................................................................................. 20-108
MEASURING COMPRESSION PRESSURE.............................................................................................. 20-109
MEASURING BLOW-BY PRESSURE ........................................................................................................ 20- 111
MEASURING ENGINE OIL PRESSURE .................................................................................................... 20- 112
HANDLING OF FUEL SYSTEM EQUIPMENT ........................................................................................... 20-113
REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT ................................................. 20- 113
MEASUREMENT OF FUEL PRESSURE ................................................................................................... 20- 114
AIR BLEEDING FROM FUEL CIRCUIT ..................................................................................................... 20- 115
INSPECTION OF LEAKAGE FROM FUEL SYSTEM................................................................................. 20- 117
TESTING AND ADJUSTING FAN BELT TENSION.................................................................................... 20- 119
TESTING AND ADJUSTING ALTERNATOR BELT TENSION ................................................................... 20-120
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT................................................. 20-121
INSPECTION OF SWING CIRCLE BEARING CLEARANCE..................................................................... 20-122
TESTING AND ADJUSTING TRACK SHOE TENSION ............................................................................. 20-123
TESTING AND ADJUSTING WORK EQUIPMENT, SWING,
AND TRAVEL CIRCUIT OIL PRESSURES.......................................................................................... 20-124
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE......................................................... 20-129
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE ..................................................... 20-130
INSPECTION OF SERVO PISTON STROKE ............................................................................................ 20-136
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE ......................................................................... 20-137
MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE,
AND SWING PRIORITY SELECTOR VALVE ...................................................................................... 20-140
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE........................................................................... 20-145
TESTING AND ADJUSTING TRAVEL DEVIATION.................................................................................... 20-146
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT................................... 20-148
MEASURING OIL LEAKAGE...................................................................................................................... 20-149
RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT..................................................... 20-153
BLEEDING AIR FROM EACH PART .......................................................................................................... 20-154
INSPECTION PROCEDURES FOR DIODE............................................................................................... 20-157
SPECIAL FUNCTION OF MONITOR PANEL............................................................................................. 20-158
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT .............................................................. 20-185
PREPARATION WORK............................................................................................................................... 20-186
Pm-CLINIC SERVICE ................................................................................................................................. 20-189
UNDERCARRIAGE INSPECTION ............................................................................................................. 20-196
PC750, 800-7 20-101

(1)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
symbol
Q’ty
Test, measuremnt item Part No. Part name Remarks
Measuring intake air pres-

A 799-201-2202 Boost gauge kit 1 –101 to 200 kPa {–760 to 1,500 Hg}
sure (boost pressure)
Measuring exhaust tem-
B 799-101-1502 Digital thermometer 1 –99.9 to 1,299 ºC
perature
1 799-201-9000 Handy smoke checker 1 Pollution level: 0 to 70% (With standard
Measuring exhaust gas
C color)
color 2 Purchased Smoke meter 1 (Pollution level × 1/10 C Bosch index)
Adjusting valve clearance D Purchased Feeler gauge 1 (Intake: 0.35 mm, Exhaust: 0.57 mm)
1 795-502-1590 Compression gauge 1 0 to 6.9 MPa {0 to 70 kg/cm2}
Measuring compression
E 795-471-1310 Adapter 1 For 140E-3 engine
pressure 2
6217-71-6110 Gasket 1 For 140E-3 engine
Measuring blow-by pres-
F 799-201-1504 Blow-by checker 1
sure
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil pres-
G
sure 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
1 {25, 60, 400, 600 kg/cm2}
Measuring fuel pressure H
790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
Measuring clearance of
J Purchased Dial gauge 1 With magnet
swing circle bearing
Testing and adjusting in Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
work equipment, swing, {25, 60, 400, 600 kg/cm2}
K
and travel circuit oil pres-
sures 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}

Testing and adjusting 799-101-5002 Hydraulic tester 1
L {25, 60, 400, 600 kg/cm2}
control circuit oil pressure
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting Differential pressure
control oil pressure of M 2 799-401-2701 gauge 1
piston pump
799-101-5220 Nipple 2 Size: 10 × 1.25 mm
3
07002-11023 O-ring 2
4 799-401-3200 Adapter 2 Size: 03
708-25-14140 Cap 1
1 For HPV95 + 95 pump
Testing servo piston stroke N 07000-B2065 O-ring 1
2 566-98-41120 Disc gauge 1
20-102 PC750, 800-7

(1)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
symbol
Q’ty
Test, measuremnt item Part No. Part name Remarks

1 {25, 60, 400, 600 kg/cm2}
Measuring PPC valve out-
P
put pressure 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-3200 Adapter 1 Size: 03
1 {25, 60, 400, 600 kg/cm2}
Measuring outlet pressure 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
of solenoid valve, swing
PPC shuttle valve, and Q 2 799-401-3200 Adapter 1 Size: 03
swing priority selector 3 799-401-3300 Adapter 1 Size: 04
valve
799-101-5220 Nipple 2 Size: 10 × 1.25 mm
4
07002-11023 O-ring 2
Measuring oil leakage R Purchased Measuring cylinder 1
Measuring wear of
— 796-627-1110 Wear gauge 1
sprocket
Measuring water tempera-
— 799-101-1502 Digital thermometer 1 –99.9 to 1,299 ºC
ture and oil temperature
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}

—
and pressing force 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
Measuring stroke and
— Purchased Scale 1
hydraulic drift
Measuring work equip-
— Purchased Stopwatch 1
ment speed
Measuring voltage and
— Purchased Multimeter 1
resistance
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor
panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Connector
arrangement drawing and electric circuit diagram of each system.
PC750, 800-7 20-103

(1)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

a Measure the engine speed under the following 4. Measuring all-pump relief speed
condition. 1) Start the engine and set the fuel control dial
• Engine water temperature: Within operating in the high idling position (MAX).
range 2) Set the working mode switch in the A-mode
• Hydraulic oil temperature: Within operating position.
range 3) Turn the heavy lift switch OFF.
4) Relieve the boom circuit by raising the boom
1. Preparation work and measure the engine speed.
Turn the starting switch ON and set the monitor
panel to "Monitoring". 5. Measuring heavy-lift ON + all-pump relief
a For the operating method, see "Special func- speed
tions of monitor panel". 1) Start the engine and set the fuel control dial
a Monitoring code: 01002 Engine speed in the high idling position (MAX).
01006 Engine speed 2) Set the working mode switch in the A-mode
a Code 01002 is information of the engine con- position.
troller and code 01006 is information of the 3) Turn the heavy lift switch ON.
pump controller. The engine speed can be 4) Relieve the boom circuit by raising the boom
measured with either of those codes. and measure the engine speed.
a The engine speed is displayed in rpm.
6. Measuring high idling-cut ON speed
1) Start the engine and set the fuel control dial
in the high idling position (MAX).
2) Turn the auto-decelerator switch OFF.
3) Set the work equipment control, swing con-
trol, and travel levers in neutral and meas-
ure the engine speed when the high idling-
cut function is turned ON.
a The engine speed lowers to a certain
level approx. 4 seconds after all the con-
trol levers are set in neutral. This level is
the high idling-cut ON speed.
7. Measuring auto-deceleration ON speed

2. Measuring low idling speed 1) Start the engine and set the fuel control dial
1) Start the engine and set the fuel control dial in the high idling position (MAX).
in the low idling position (MIN). 2) Turn the auto-deceleration switch ON.
2) Set the work equipment control, swing con- 3) Set the work equipment control, swing con-
trol, and travel levers in neutral and meas- trol, and travel control levers in neutral.
ure the engine speed. When the auto-decelerator operates, meas-
ure the engine speed.
3. Measuring high idling speed a The engine speed lowers to a certain
1) Start the engine and set the fuel control dial level about 6 seconds after all the levers
in the high idling position (MAX). are set in neutral. This level is the auto-
2) Set the working mode switch to the A-mode deceleration speed.
position.
3) Turn the auto-decelerator switch OFF.
4) Turn the swing lock switch ON, release the
safety lock lever, and measure the engine
speed while operating the swing control
lever finely.
a Operate the swing control lever to a de-
gree that the PPC oil pressure switch is
turned ON. Do not relieve the swing cir-
cle.
20-104 PC750, 800-7

(1)
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

a Measuring instruments for intake air pressure 4. Run the engine at a medium or higher speed
(boost pressure) and drain the oil from the hose.
a Insert the connecting parts of the gauge and
Symbol Part No. Part Name hose about a half and open the self-seal on
the hose side repeatedly, and the oil will be
A 799-201-2202 Boost gauge kit
drained.
a If Pm kit is available, the air bleed coupling
a When installing and removing the measuring (790-261-1130) inside the kit can also be
instruments, take care not to touch a hot part of used.
the engine. a If oil is left in the hose, the gauge does not
a Measure the intake air pressure (boost pres- work. Accordingly, be sure to drain the oil.
sure) under the following condition.
• Engine water temperature: Within operating 5. Set the working mode switch to A mode and turn
range the heavy lift switch ON.
• Hydraulic oil temperature: Within operating
range 6. Run the engine at high idling and measure the
air supply pressure (boost pressure) when the
1. Open the engine compartment cover on the boom RAISE circuit is relieved.
counterweight side.
2. Remove intake air pressure pickup plug (1).
7. After completing the measurement, remove the

measuring equipment and set to the original
condition.
3. Install nipple [1] of boost gauge kit A and con-
nect gauge [2].
PC750, 800-7 20-105

(1)
TESTING AND ADJUSTING MEASUREMENT OF EXHAUST GAS TEMPERATURE
MEASUREMENT OF EXHAUST GAS TEMPERATURE

a Measuring instrument of exhaust gas tempera- 3. Install sensor [1] of digital thermometer B and
ture connect them to meter [2].
a Clamp the wiring harness of the digital tem-
Symbol Part No. Part Name perature gauge so that it does not touch any
B 799-101-1502 Digital thermometer high temperature part during the measure-
ment.
k Wait for the temperature of the exhaust manifold
to go down before removing or installing the
measuring equiment.
a Measure the exhaust temperature under the fol-
lowing conditions.
• Coolant temperature: Within operating range
range
1. Open the engine compartment cover on the

counterweight side and remove turbocharger
heat insulation cover (1).
4. Procedure for measuring maximum exhaust

temperature for troubleshooting
Operate the machine actually and measure the
maximum exhaust temperature.
a Set the digital thermometer in the PEAK
mode.
5. Procedure for measuring exhaust temperature

periodically for preventive maintenance (Pm
Clinic), etc.
1) Set the working mode switch in the A-mode
position and turn the heavy lift switch ON.
2. Remove exhaust temperature pickup plug (2). 2) Run the engine at high idling, relieve the
boom circuit by raising the boom, and meas-
ure the exhaust temperature.
a Measure the exhaust temperature after
it is stabilized.
6. After completing the measurement, remove the

measuring equipment and set to the original
condition.
20-106 PC750, 800-7

(1)
TESTING AND ADJUSTING MEASUREMENT OF EXHAUST GAS COLOR
MEASUREMENT OF EXHAUST GAS COLOR

a Measuring instrument of exhaust gas color
Symbol Part Number Part Name
1 799-201-9000 Handy smoke checker
C
2 Purchased Smoke meter
k Be careful not to touch hot areas when mount-

ing and removing the measuring instrument.
a When air source or electric power supply is not
a v a i l a bl e i n fi e l d , u s e C1 Ha n d y S m ok e
Checker, but use C2 Smoke Meter, when
recording official data.
a Measure exhaust gas color under the following
conditions:
2) Connect the prove hose, the receptacle of
• Engine water temperature:Within the operat-
the accelerator switch and the air hose to
ing temperature range.
the smoke meter C2.
a The supply air pressure shall be less
1. Measurement with C1, Handy Smoke Check-
than 1.5 MPa {15 kg/cm2}
er
3) Connect the power cord to an AC100V
1) Set a filter paper in the handy smoke
receptacle.
checker C1.
a Before connecting the power cord, make
2) Insert the exhaust gas suction port in the
sure that the power switch of the smoke
exhaust pipe (1).
meter is turned off.
3) Start the engine.
4) Loosen the cap nut of the suction pump and
4) Operate the handle of the smoke checker
set a filter paper there.
C1, and adhere exhaust gas to the filter
a Set the filter paper accurately so that ex-
paper when accelerating the engine quickly
haust gas does not leak out.
or at a high idling.
5) Turn on the power switch of the smoke
meter C2.
5) Remove the filter paper and compare the

color on the filter paper with the accessory
6) Start the engine.
scale.
7) When accelerating the engine quickly or at a
6) After the measurement, remove the meas-
high idling, step down the accelerator pedal
uring instrument and return the engine to
of the smoke meter C2, and collect exhaust
the original state.
gas in the filter paper.
8) Place the filter paper contaminated with
2. Measurement with Smoke Meter C2
exhaust gas on new filter papers (more than
1) Insert the probe [1] of the smoke meter C2,
10 sheets) in the filter paper holder and read
in the outlet of the exhaust pipe (1) and fix it
the indicated value.
to the exhaust pipe with clip.
9) After the measurement, remove the meas-
uring instrument and return the engine to
the original state.
PC750, 800-7 20-107

(1)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

a Adjusting tools for valve clearance 3. Insert feeler gauge D in clearance b between
rocker arm (3) and crosshead (4), and turn
Symbol Part No. Part Name
adjustment screw (5) to adjust the valve clear-
D Purchased Feeler gauge ance.
a With feeler gauge D inserted, turn the adjust-
1. Remove the engine hood assembly and all cyl- ment screw and adjust until the clearance is
inder head covers (1). a sliding fit.
4 Engine hood assembly: 260 kg 4. Tighen locknut (6) to hold adjustment screw (5)
3 Locknut:
in position.
53.0 – 64.7 Nm {5.4 – 6.6 kgm}

a After tightening the locknut, check the valve
clearance again.
2. Rotate the crankshaft in the normal direction to

align [1.6 TOP] line a on the damper with pointer
(2), and set the No.1 cylinder compression to
top dead center.
a Check the pointer from the air compressor
side. 5. Rotate the crankshaft 120° each time in the nor-
a Crank the engine with the hexagonal part at mal direction and repeat Steps 2 - 4 to adjust the
the water pump drive shaft on the alternator valve clearance of each cylinder according to
side. the firing order.
a At the compression top dead center, the a Firing order: 1-5-3-6-2-4
rocker arm of the No. 1 cylinder can be
moved by hand an amount equal to the valve 6. After comleting the adjustment, set to the origi-
3 Mounting bolt of cylinder head cover:

clearance. If the rocker arm does not move, nal condition.
it is not at the compression top dead center,
so rotate the crankshaft one more turn. 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
20-108 PC750, 800-7

(1)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

a Measuring instruments for compression pres- a Pass a wire, etc. under the fuel path project-
sure ed sideways and pull up the injector (Do not
pry the injector top up).
1 795-502-1590 Compression gauge
E 795-471-1310 Adapter
2
6217-71-6110 Gasket
a When measuring the compression pressure,

take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating
part.
a Measure the compression pressure under the
following condition.
• Engine oil temperature: 40 – 60°C
1. Remove the engine hood assembly and head 4. Install adapter E2 and connect it to compression
cover (1) of the cylinder to measure the com- gauge E1.
pression pressure.
3 Mounting bolt:
a Secure the adapter with the injector holder.
4 Engine hood assembly: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}

Approx. 260 kg a Apply a little amount of engine oil to the con-
necting parts of the adapter and gauge so
that air will not leak easily.
5. Install rocker arm assembly (2) and adjust the
3 Mounting bolt:
valve clearance.
93 – 103 Nm {9.5 – 10.5 kgm}

a See ADJUSTING VALVE CLEARANCE.
2. Remove rocker arm assembly (2).

a Referring to ADJUSTING VALVE CLEAR-
ANCE, set the cylinder to be measured at the
compression top dead center so that you can
work easily.
3. Disconnect fuel high-pressure tube (3) and

remove the injector wiring harness and injector
(4).
a Use a high-pressure pipe ring wrench (on
the market) to disconnect and connect the
fuel high-pressure tube. At this time, loosen
the clamps on the common rail side and at
the intermediate part.
a Disconnect the terminal of the injector wiring
harness on the injector side and the bracket
on the rocker housing side and remove the
injector wiring harness (Loosen the terminal
nuts alternately).
PC750, 800-7 20-109

(1)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
6. Disconnect engine intermediate connectors E21 3) Tighten sleeve nut (14) of the fuel high-pres-
(5) and E22 (6). sure tube to injector (11) lightly.
k If these connectors are not disconnected,

a Use a high-pressure pipe ring wrench
(on the market) to disconnect and con-
the engine may start while your are measur- nect the fuel high-pressure tube.
ing, and that is dangerous. Accordingly, be a Tighten the sleeve nut lightly until it is
k Cover the connector on the controller side

sure to disconnect the connectors. stopped by the injector.
3 Mounting bolt:
4) Tighten mounting bolt (13) securely.
(body side) with a vinyl sheet, etc. to pre-
vent electric leakage and grounding fault. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
5) Tighten sleeve nut (14) of the fuel high-pres-
3 Sleeve nut:
sure tube securely.
39.2 – 49.0 Nm {4 – 5 kgm}

6) Tighten the intermediate clamp of the fuel
high-pressure tube.
7) Install the injector wiring harness.
a Tighten the terminal nuts at the injector
3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}

top alternately.
7. Turn the starting switch ON and prepare for

measuring the engine speed with the monitor
panel.
a See MEASURING ENGINE SPEED.
8. Crank the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it is
stabilized.
a When measuring the compression pressure,
measure the engine speed, too, and check a After installing the rocker arm assembly, ad-
that it is in the measurement condition range. just the valve clearance. For details, see
3 Rocker arm assembly mounting bolt:

ADJUSTING VALVE CLEARANCE.
9. After finishing measurement, remove the meas-
uring instruments and return the removed parts. 93 – 103 Nm {9.5 – 10.5 kgm}
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Assemble injector (11) and holder (12)
together and set them to the mounting posi-
tion of the cylinder head.
a When setting the injector, pull the fuel
high-pressure tube to outside of the cyl-
inder head so that the threads of the in-
jector will not interfere with the taper seal
of the fuel high-pressure tube.
2) Tighten mounting bolt (13) temporarily.
a Tighten the mounting bolt to a degree
that you can move the injector.
20-110 PC750, 800-7

(1)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

a Measuring instruments for blow-by pressure
F 799-201-1504 Blow-by checker
a Measure the blow-by pressure under the follow-

ing conditions.
range
1. Install the nozzle of blow-by checker F to blow-

by hose (1).
2. Connect the nozzle [1] and gauge [2] with the

hose.
3. Start the engine and set the working mode

switch to the A-mode position.
4. Run the engine at high idling, relieve the arm cir-

cuit by moving the arm IN, and measure the
brake oil pressure.
5. After finishing measurement, remove the meas-

uring instruments and return the removed parts.
PC750, 800-7 20-111

(1)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE
a Measuring instruments for engine oil pressure 4. Start the engine and measure the oil pressure
with the engine at low idling and high idling.
799-101-5002 Hydraulic tester
1
G 790-261-1203 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
a Measure the engine oil pressure under the fol-

lowing conditions.

control valve side.
2. Remove engine oil low-pressure switch (1) or oil

high-pressure switch (2). 5. After completing the measurement, remove the
a After removing the switch, wind the wiring measuring equipment and set to the original
3 Oil pressure switch:

harness with tape to prevent it from contact- condition.
ing the cylinder block.
2.9 – 5.9 Nm {0.3 – 0.6 kgm}
3. Install nipple [1] of hydraulic tester G1 and con-

nect them to hydraulic tester G2.
20-112 PC750, 800-7

(1)
HANDLING OF FUEL SYSTEM EQUIPMENT
TESTING AND ADJUSTING REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT
HANDLING OF FUEL SYSTEM REMAINING PRESSURE

EQUIPMENT RELIEF FROM FUEL SYSTEM
EQUIPMENT
a Precautions in Inspection and Maintenance of a While the engine is rotating, pressures occur in
Fuel System Equipment the low pressure circuit and the high pressure
The common rail type fuel injection system circuit of the fuel system.
(CRI) is composed of more precise components Low pressure circuit : Among Feed pump – Fuel
than the usual fuel injection pump and nozzle filter – Fuel supply pump
and will probably get out of order when foreign High pressure circuit : Among Fuel supply pump
matters enters the system. – Common rail – Fuel injector
During inspection and maintenance of the fuel a When 30 seconds elapse after the engine
system, pay more attention to foreign matters stopped, pressures in both the low pressure cir-
than in case of usual fuel injection pumps and cuit and the high pressure circuit drop to the
wash the system carefully with clean fuel if dusts safe level automatically.
enter the system. a Since pressure remaining in the fuel system
should be relieved certainly before inspection of
a Precautions in Replacement of Fuel Filter Car- the fuel system and mounting and removing of
tridge equipment, be sure to observe the following pre-
k Inspect the fuel system or mount or remove

Be sure to use genuine fuel filter cartridge of cautions:
Komatsu.
The common rail type fuel injection system equipment more than 30 seconds later after the
(CRI) is composed of more precise components engine stopped and after pressure remaining in
than the usual fuel injection pump and nozzle the fuel system is relieved. (Pressure remains in
and is equipped with special filter with highly the fuel system right after the engine stopped,
efficient filtration performance to prevent foreign so do not start any work until 30 seconds
matters from entering the system. elapse.)
Therefore, be sure to use genuine filters only.
Otherwise, the fuel system will possibly get out
of order.
PC750, 800-7 20-113

(1)
TESTING AND ADJUSTING MEASUREMENT OF FUEL PRESSURE
MEASUREMENT OF FUEL PRESSURE

a Measuring Instrument of Fuel Pressure 4. Start the engine and measure fuel pressure at
the time of high idling.
a If the fuel pressure is in the following range,
799-101-5002 Hydraulic tester it is normal.
1 Digital type hydraulic Fuel pressure: 0.15 – 0.3 MPa {1.5 – 3 kg/cm2}
H 790-261-1203
tester
2 799-401-2320 Hydraulic tester
a Measure fuel pressure in the low pressure circuit

among the feed pump – the fuel filter – the fuel
k Since very high pressure are generated in the

supply pump.
high pressure circuit among the fuel supply

pump – the common rail – the fuel injector, they
cannot be measured in the circuit.

control valve side.
5. After the measurement, return the circuit to the
2. Remove the fuel pressure measurement plug original state.
(1).
3. Attach the nipple [1] of the hydraulic tester H1,

and connect the hydraulic tester H2.
20-114 PC750, 800-7

(1)
TESTING AND ADJUSTING AIR BLEEDING FROM FUEL CIRCUIT
AIR BLEEDING FROM FUEL CIRCUIT
a When the fuel has run out, or after mounting or

removing any device to or from the fuel circuit,
bleed air from the circuit as follows:
a Open the engine compartment cover on the
control valve side.
1. Remove the fuel filter (1), fill the circuit with the
fuel and mount the filter again.
a Fill the circuit with clean fuel and be careful
to prevent dusts from entering the circuit.
a Pour the fuel in the inlet ports (1a) (at 8 plac-
es) of the filter. The portion (1b) is the outlet
port (clean side) after filtration, and do not
pour the filter in this port.
a When clean fuel is not readily available, do
not remove the fuel filter and fill the filter with
the fuel by operating the priming pump.
PC750, 800-7 20-115

(1)
TESTING AND ADJUSTING AIR BLEEDING FROM FUEL CIRCUIT
2. Remove the air bleeding plug (2a) from the fuel

filter and operate the priming pump (3).
a Keep operating the priming pump until the
fuel comes out of the plug hole, and attach
the plug to the fuel filter when checking the
3 Air bleeding plug :

fuel.
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3. Remove the plug (2b) from the fuel filter and

operate the priming pump (3).
fuel comes out of the plug hole, and attach
the plug to the fuel filter when checking the
3 Air bleeding plug :

fuel.
3.8 – 6.9 Nm {0.4 – 0.7 kgm}
4. Loosen the air bleeder (4) on the fuel supply

pump and operate the priming pump (3) 90 to
100 times.
fuel comes out of the bleeder, and tighten the
bleeder when you could check the fuel.
Then, operate the priming pump several
3 Air bleeder :
times until it become tight.
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
5. Crank the engine with the starting motor and

start the engine.
a When the engine is cranked, air is bled auto-
matically from the high pressure circuit.
a When the engine does not start, air would
not have been bled sufficiently from the low
pressure circuit. Execute the procedures
again from Step 2.
20-116 PC750, 800-7

(1)
TESTING AND ADJUSTING INSPECTION OF LEAKAGE FROM FUEL SYSTEM
INSPECTION OF LEAKAGE FROM FUEL SYSTEM

k Since very high pressures are generated in the 7. Check if fuel is leaking from the fuel pipe and
high pressure fuel circuit, there is a danger of equipment.
getting fire if fuel leaks while the engine is run- a Check if fuel is leaking from the high pres-
ning. sure circuit, mainly from the area where color
After inspecting the fuel circuit or mounting or checker was sprayed.
removing equipment to or from the fuel circuit, a When finding fuel leakage, repair the rele-
execute the following procedures to check if fuel vant portions. Then, repeat the procedures
is leaking. from Step 2 to check that there is no leakage
a Clean and degrease the engine body and the from the relevant portions.
area around before inspection so that fuel leak-
age can be checked easily. 8. Start the engine and keep low idling. Apply any
load to the engine.
1. Spray color checker (developer) to the connec- a Relieve the arm IN.
tions of the fuel supply pump, the common rail,
the fuel injector and the high pressure pipe. 9. Check if fuel is leaking from the fuel pipe and
equipment.
2. Start the engine, keep the speed below 1,000 a Check if fuel is leaking from the high pres-
rpm and stop the engine when the rotation sure circuit, mainly from the area where color
became stable. checker was sprayed.
a When finding fuel leakage, repair the rele-
3. Check if fuel is leaking from the fuel pipe and vant portions. Then, repeat the procedures
equipment. from Step 2 to check that there is no leakage
a Check if fuel is leaking from the high pres- from the relevant portions.
sure circuit, mainly from the area where color a When no leakage is found, end the inspec-
checker was sprayed. tion.
vant portions. Then, repeat the procedures
from Step 2 to check that there is no leakage
from the relevant portions.
4. Start the engine and keep low idling.
5. Check if fuel is leaking from the fuel pipe and

equipment.
a Check if fuel is leaking from the high pres-
sure circuit, mainly from the area where color
checker was sprayed.
vant portions. Then, repeat the procedures
from Step 2 to check that there is no leakage
from the relevant portions.
6. Start the engine and keep high idling.
PC750, 800-7 20-117

(1)
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

a Adjust the engine speed sensor for the pump
controller as follows.
a The engine G rotation sensor and engine Ne
rotation sensor for the engine controller cannot
be adjusted.
a Open the engine compartment cover on the
control valve side. Before adjusting speed sen-
sor (1), remove it and check that its tip is free
from steel chips and flaws, and then install it
again.
1. Screw in sensor (1) until the tip contacts the tip
2 Thread: Hydraulic sealant

of the tooth of flywheel ring gear (2).
2. Turn sensor (1) back 1/2 – 2/3 turns.

a This makes clearance a of 0.75 – 1.00 mm
between the tip of the sensor and the tip of
the gear tooth.
3 Nut: 69 – 74 Nm {7.0 – 7.5 kgm}

3. Hold sensor (1) in position with nut (3).
4. After finishing adjustment, check that the moni-

tor panel displays the engine speed normally in
the monitoring function.
a For the monitoring function, see "Special
functions of monitor panel".
a Monitoring code: 01006 Engine speed
20-118 PC750, 800-7

(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING FAN BELT TENSION
Testing Adjusting
The tension of this fan belt does not need to be 1. Tighten adjustment screw (2) until it touches
tested or adjusted until when the belt is replaced. bracket (5).
Replacement 2. Tighten adjustment screw (2) 2 more turns and
3 Locknut:
1. Open the engine compartment cover on the secure it with locknut (1).
counterweight side.
245.0 – 308.7 Nm {25.0 – 31.5 kgm}
2. Loosen locknut (1), and then fully loosen adjust-
ment screw (2) toward the counterweight. a If any clearance is made between adjustment
screw (2) and bracket (5), eliminate it by the
3. Insert a bar about 50 cm long in the hole (ø18) above procedure.
of tension pulley (3) and press tension pulley (3) a If the fan belts creak, adjust them by the above
toward the crank pulley to loosen the belt. procedure.
4. Replace 4 V-belts (4) and return tension pulley

(3) to their original positions.
a Replace the 4 V-belts as a set.
PC750, 800-7 20-119

(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
Testing procedure Adjustment procedure

1. Open the engine compartment cover on the a Adjust the belt according to the following proce-
counterweight side. dure when the belt deflection is not normal.
2. Measure the belt deflection (a) when pushing a 1. Loosen nuts and bolts (1), (2), (3) and (4) in this
point midway between the alternator pulley and order.
the drive pulley with the finger.
2. Turn nut (5) to move alternator (6), and adjust
a Deflection (a) when pressing force is approx. the belt tension.
58.8 N {approx. 6 kg}: 10 – 15 mm a Nut (5):
• It is moved to the side that belt is loos-
ened when fastening it clockwise.
• It is moved to the side that belt is ten-
sioned when loosening it counterclock-
wise.
a Test for breakage of each pulley, friction of
V-ditch, friction of belt, and contact between
belt and V-ditch.
a Replace it with new belt if it was too
stretched so that adjustability was lost, or cut
and crack occurred.
3. Tighten nuts and bolts (4), (3), (2) and (1) in this
order.
a When the belt was replaced, readjust it after
one-hour operation.
20-120 PC750, 800-7

(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR

BELT
Testing 3. Tighten nuts and bolts in the order of (4), (3), (2),
1. Open the engine compartment cover on the and (1).
control valve side and remove the cover of the a If the belts were replaced, adjust their ten-
air conditioner compressor belt. sion again after operating the machine for 1
hour.
2. Press the intermediate point between the air
conditioner compressor pulley and drive pulley
with a finger and measure deflection (a).
a Deflection (a) when pressing force is approx.
58.8 N {approx. 6 kg}: 10 – 15 mm
Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.
1. Loosen the bolts and nuts in the order of (1), (2),

(3), and (4).
2. Rotate nut (5) to move compressor (6) and

adjust the belt tension.
a If nut (5) is
• tightened clockwise, the belt is loos-
ened.
• loosened counterclockwise, the belt is
tensed.
a Check each pulley for breakage, check the
V-grooves and V-belts for wear, and check
that the V-grooves and V-belts are in good
contact with each other.
a If the belts are so lengthened that their ten-
sion cannot be adjusted any more or they
have a cut or a crack, replace them.
PC750, 800-7 20-121

(1)
TESTING AND ADJUSTING INSPECTION OF SWING CIRCLE BEARING CLEARANCE
INSPECTION OF SWING CIRCLE BEARING CLEARANCE

a Inspection Device of Swing Circle Bearing 3. Set the dial gauge J to the zero point.
Clearance
4. Arrange the arm almost at right angles to the
ground and lower the boom until the front leg of
J Purchased
Dial gauge the machine body rises.
(with magnet) a At the time, the front of the upper structure
rises and its rear lowers.
a When measuring swing circle bearing clearance
on a machine, follow the procedures below:
a For the standard values, see STRUCTURE,
FUNCTION AND MAINTENANCE STANDARD,
"Swing circle".
1. Fix the dial gauge J to the track frame (center

frame) and bring the stylus to the outer race end
face.
a Set the dial gauge to the front or to the rear.
5. At the time, read the value on the dial gauge J.

This value on the dial gauge indicates the swing
circle bearing clearance.
k During the measurement, never place

hands and legs below the undercarriage.
6. Return the work equipment to the state in Para-

graph 2 and make sure that the dial gauge J has
returned to the zero point. If not, repeat Steps 2
2. Set the work equipment to the maximum reach to 5.
and set the bucket tip to the height of the revolv-
ing frame lower face.
a At the time, the front of the upper structure
lowers and its rear rises.
20-122 PC750, 800-7

(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION

TESTING ADJUSTING
1. Travel the machine forward by the length of a If the track shoe tension is not proper, adjust it in
track on ground, keeping the engine at low the following manner.
idling, and stop the machine slowly.
1. When the tension is too strong
2. Place wood bar [1] on the track shoe between Discharge grease by loosening valve (3).
k Do not loosen valve (3) by more than one

second carrier roller (1) and third carrier roller
(2).
a L beam is recommended for bar [1], because turn, because grease will spurt due to its in-
of its deflection-free nature. ternal high pressure.
3. Measure max. clearance (a) between bar [1] 2. When the tension is too weak
and the track shoe. Add grease through grease fitting (4).
• Max. standard clearance (a): 10 – 30 mm a If the normal track shoe tension is not re-
stored even after greasing, move the ma-
chine slowly back and forth.
PC750, 800-7 20-123

(1)
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND
TESTING AND ADJUSTING TRAVEL CIRCUIT OIL PRESSURES

TRAVEL CIRCUIT OIL PRESSURES
a Testing and adjusting instruments for work a Either quick coupler (2) or (4) can be
equipment, swing, and travel circuit oil pres- used to measure the rear pump (No. 1 R
sures + No. 2 R) circuit oil pressure.
a The relief pressure of the boom LOWER
Symbol Part Number Part Name circuit can be measured only in the front
799-101-5002 Hydraulic tester pump circuit.
K a The relief pressure of the bucket DUMP
790-261-1203 Digital hydraulic tester
circuit can be measured only in the rear
pump circuit.
MEASUREMENT a The relief pressure of the swing circuit
a Mesure the work equipment, swing and travel can be measured only in the front pump
circuit oil pressures under the following condi- circuit.
tions: a Use the oil pressure gauges of 58.8 MPa
• Hydraulic oil temperature: Within operating {600 kg/cm2}.
temperature range • (1), (2) : Quick couplers for No. 1 pump
a The work equipment, swing, and travel circuit oil
pressures can be checked in the monitoring
function of the monitor panel, too. (For the oper-
ating method, see "Special functions of monitor
panel".)
• Monitoring code: 01100 F pump pressure
01101 R pump pressure
• The pump oil pressure is displayed in MPa
{kg/cm2, PSI).
• (3), (4) : Quick couplers for No. 2 pump
1. Preparation work
k Lower the work equipment to the ground

and stop the engine. Operate the control le-
vers several times to release the residual
pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
release the internal pressure of the hydrau-
lic tank.
1) Open the pump compartment cover.
2) Connect oil pressure gauges [1] of hydraulic
tester K to quick couplers (1) - (4) installed
to the outlet of each pump of the circuit to be
measured.
a Either quick coupler (1) or (3) can be
used to measure the front pump (No. 1 F
+ No. 2 F) circuit oil pressure.
20-124 PC750, 800-7

(1)
2. Measuring work equipment circuit oil pres-

sure
1) Measuring normal relief pressure
i) Start the engine and set the working
mode switch to the A-mode position.
ii) Run the engine at high idling, relieve
each cylinder singly at the stroke end,
and measure the oil pressure.
a The main relief valves of the right and
left control valves relieve on the low-
pressure setting side.
a If the boom cylinder is relieved at the
LOWER stroke end, the safety-suction
valve on the boom head side of the right
4-spool control valve relieves on the low- 3. Measuring swing circuit oil pressure
pressure setting side (The set pressure 1) Start the engine and set the working mode
of the safety-suction valve is lower than switch in the A-mode position.
that of the main relief valve). 2) Turn the swing lock switch ON.
2) Measuring relief pressure during heavy lift 3) Run the engine at high idling, relieve the
operation swing motor, and measure the oil pressure.
i) Start the engine and set the working a The safety valves of the front and rear swing
mode switch in the A-mode position. motors relieve. (The set pressure of the
ii) Turn the heavy lift switch ON. safety valves is lower than that of the main
iii) Run the engine at high idling, relieve the relief valve.)
boom cylinder singly at the RAISE stroke
end, and measure the oil pressure.
a The heavy lift function operates only
when the boom RAISE operation is per-
formed singly.
a The main relief valves of the right and
left control valves relieve on the high-
3) Measuring relief pressure during machine
push-up operation
i) Start the engine and set the working
mode switch in the A-mode position.
ii) Turn the machine push-up switch ON.
iii) Run the engine at high idling, relieve the
boom cylinder singly at the LOWER
stroke end, and measure the oil pres-
sure.
a Since the set pressure of the safety-suc-
tion valve on the boom head side of the
right 4-spool valve rises higher than the
set pressure of the main relief valve, the
main relief valve relieves on the low-
PC750, 800-7 20-125

(1)
4. Measuring travel circuit oil pressure ADJUSTING

1) Start the engine and lock the travel mecha- a Do not adjust any safety valve other than the
nism. swing motor safety valve.
k Put pin [2] between the sprocket and

a When adjusting the main relief valves of the left
5-spool valve and right 4-spool valve, remove
track frame to lock the travel mecha- the control valve top cover.
nism securely.
1. Adjusting main relief valve (high-pressure
setting) of left 5-spool control valve
a If the work equipment oil pressure in the front
pump circuit (during heavy lift operation) and
the left travel oil pressure are abnormal, ad-
just the high-pressure setting side of main
relief valve (5) of the left 5-spool control
valve according to the following procedure.
2) Run the engine at high idling, relieve the

travel motor, and measure the oil pressure.
a The main relief valves of the right and left
control valves relieve on the high-pressure
setting side.
a The high pressure setting is the state in

which the 2-stage relief solenoid valve is
turned ON and the pilot pressure is applied
to the changeover port.
1) Disconnect hose (6).
2) Loosen locknut (7) and set elbow (8) free.
3) Fix holder (9) and loosen locknut (10).
4) Turn holder (9) to adjust the pressure.
a If the holder is
• turned to the right, the pressure ris-
es.
• turned to the left, the pressure low-
ers.
a Pressure changed by 1 turn of holder:
21.8 MPa {222 kg/cm2}
20-126 PC750, 800-7

(1)
3 Locknut:
5) Fix holder (9) and tighten locknut (10). 2. Adjusting main relief valve (low-pressure set-
ting) of left 5-spool control valve
93 – 123 Nm {9.5 – 12.5 kgm} a If the work equipment oil pressure in the front
a If the high-pressure setting side is ad- pump circuit (during normal relief operation)
justed, the low-pressure setting side is abnormal or the high-pressure setting side
changes. Accordingly, adjust the low- was adjusted, adjust the low-pressure set-
pressure setting side, too. ting side of main relief valve (5) of the left 5-
spool control valve according to the following
procedure.
a The low-pressure setting is the state in which
the 2-stage relief solenoid valve is turned
OFF and the pilot pressure is not applied to
the changeover port.
1) Disconnect hose (6).
2) Loosen locknut (7) and set elbow (8) free.
3) Fix union (11) and loosen locknut (12).
4) Turn union (11) to adjust the pressure.
a If the union is
es.
6) Fix elbow (8) and tighten locknut (7). ers.
7) Connect hose (6). a Pressure changed by 1 turn of union:
8) After finishing adjustment, check the oil 21.8 MPa {222 kg/cm2}
pressure again according to the above
3 Locknut:
described measurement procedure. 5) Fix union (11) and tighten locknut (12).
78 – 93 Nm {8.0 – 9.5 kgm}
6) Fix elbow (8) and tighten locknut (7).

7) Connect hose (6).
8) After finishing adjustment, check the oil
described measurement procedure.
PC750, 800-7 20-127

(1)
3. Adjusting main relief valve (high-pressure • (15): Safety valve of rear swing motor
setting) of right 4-spool control valve
a If the work equipment oil pressure in the rear
pump circuit (during heavy lift operation) and
the right travel oil pressure are abnormal, ad-
just the high-pressure setting side of main
relief valve (13) of the right 4-spool control
valve according to the following procedure.
1) Fix adjustment nut (16) and loosen locknut

(17).
k Do not remove the adjustment nut. If it

is removed, the internal parts may
come off.
2) Turn adjustment nut (16) to adjust the pres-
a Adjust the right 4-spool control valve similar- sure.
ly to the left 5-spool control valve. a If the adjustment nut is
4. Adjusting main relief valve (low-pressure set- es.
ting) of right 4-spool control valve • turned to the left, the pressure low-
a If the work equipment oil pressure in the rear ers.
pump circuit (during normal relief operation) a Pressure changed by 1 turn of adjust-
is abnormal or the high-pressure setting side ment nut: 3.6 MPa {37 kg/cm2}
was adjusted, adjust the low-pressure set- 3) Fix adjustment nut (16) and tighten locknut
3 Locknut:
ting side of main relief valve (13) of the right (17).
4-spool control valve according to the follow-
ing procedure. 147 –186 Nm {15 – 19 kgm}
a Adjust the right 4-spool control valve similar-
ly to the left 5-spool control valve.
5. Adjusting swing motor safety valve

a If the relief pressure of the swing motor is ab-
normal, adjust safety valves (14) and (15) of
the swing motor according to the following
procedure.
• (14): Safety valve of front swing motor

20-128 PC750, 800-7

(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE

a Instruments for testing and adjusting control cir- Adjusting
cuit oil pressure a When adjusting the control relief valve, open the
hydraulic tank rear cover.
Symbol Part Number Part Name a If the control circuit oil pressure is abnormal,
799-101-5002 Hydraulic tester adjust control relief valve (2) according to the
L following procedure.
Measuring
a Measure the control circuit oil pressure under
the following condition.
k Lower the work equipment to the ground

range
and stop the engine. Operate the control le-

vers several times to release the residual
pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
release the internal pressure of the hydrau-
lic tank.
1. Remove cap (3).
1. Open the pump compartment cover.
2. Fix adjustment screw (4) and loosen locknut (5).
2. Connect oil pressure gauge [1] of hydraulic
tester L to quick coupler (1) installed to the out- 3. Turn adjustment screw (4) to adjust the pres-
let of the control pump. sure.
a Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCK-
WISE.
• To DECREASE pressure, turn COUN-
TERCLOCKWISE.
3 Locknut: 9.8 Nm {1 kgm}

4. Fix adjustment screw (4) and tighten locknut (5).
3. Run the engine at high idling, set the work

equipment/swing lever and travel lever in neu-
tral, and measure the oil pressure.
5. After completion of adjustment, repeat the pro-

cedure in above to check the set pressure
again.
PC750, 800-7 20-129

(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE

a Devices for inspecting and measuring piston a Use the oil pressure gauges of 5.9 MPa
pump control oil pressure {60 kg/cm2}.

1
Differential pressure
2 799-401-2701
M gauge
799-101-5220 Nipple (10 × 1.5 mm)
3
07002-11023 O-ring
4 799-401-3200 Adapter (Size: 03)
MEASUREMENT
a Measure the piston pump control oil pressure
under the following conditions: 4) Start the engine and set the working mode
• Hydraulic oil temperature: Within the operat- switch in the A-mode position.
5) Set all the control levers in neutral and
k Lower the work equipment to the ground and
ing range
measure the TVC valve output pressure
stop the engine. Operate the control levers sev- under the following condition.
eral times to release the residual pressure in the i) Set all the control levers in neutral.
piping, and then loosen the oil filler cap of the ii) Run the engine at high idling and meas-
hydraulic tank slowly to release the internal ure the output pressure.
pressure of the hydraulic tank. 6) Relieve the boom circuit by raising the boom
(normally), and measure the TVC valve out-
1. Measuring TVC valve output pressure put pressure under the following condition.
a Since the TVC valve output pressure varies i) Turn the heavy lift switch OFF.
with the discharge pressure of each pump, ii) Run the engine at high idling, relieve the
check that the oil pressure in the work equip- boom circuit by raising the boom, and
ment, swing, and travel circuits is normal be- measure the output pressure.
fore starting measurement. 7) Turn the heavy lift switch ON, relieve the
a Since the basic pressure of the TVC valve boom circuit by raising the boom, and meas-
output pressure is the control circuit pres- ure the TVC valve output pressure under
sure, check that the control circuit pressure the following condition.
is normal before starting measurement. i) Turn the heavy lift switch ON.
1) Open the undercover of the No. 1 pump. ii) Run the engine at high idling, relieve the
2) Remove oil pressure pickup plug (1) of the boom circuit by raising the boom, and
No. 1 front pump. measure the output pressure.
3) Install nipple M3 and connect oil pressure 8) After finishing measurement, remove the
gauge [1] of hydraulic tester M1. measuring instruments and return the
removed parts.
20-130 PC750, 800-7

(1)
2. Measuring CO-NC valve output pressure 7) Drive the travel motor idle and measure the
1) Open the undercover of the No. 2 pump. CO-NC valve output pressure under the fol-
2) Remove oil pressure pickup plugs (2) and lowing condition.
(3) of the No. 2 pump. i) Raise the track shoe to be measured by
• (2): For front pump circuit using the boom and arm.
• (3): For rear pump circuit ii) Run the engine at high idling, drive the
travel motor idle (with the lever at the
stroke end), and measure the output
pressure.
8) Turn the heavy lift switch ON, relieve the
boom circuit by raising the boom, and meas-
ure the output pressure under the following
condition.
i) Turn the heavy lift switch ON.
ii) Run the engine at high idling, relieve the
boom circuit by raising the boom, and
measure the output pressure.
3) Install nipple M3 and connect oil pressure

gauge [1] of hydraulic tester M1.
a Use the oil pressure gauges of 5.9 MPa
{60 kg/cm2}.
4) Start the engine and set the working mode

switch in the A-mode position.
5) Set all the control levers in neutral and
measure the CO-NC valve output pressure
under the following condition.
i) Set all the control levers in neutral.
ii) Run the engine at high idling and meas- 9) After finishing measurement, remove the
ure the output pressure. measuring instruments and return the
6) Relieve the boom circuit by raising the boom removed parts.
(normally) and measure the CO-NC valve
output pressure under the following condi-
tion.
i) Turn the heavy lift switch OFF.
ii) Run the engine at high idling, relieve the
boom circuit by raising the boom, and
measure the output pressure.
PC750, 800-7 20-131

(1)
3. Measuring jet sensor output differential pres-

sure of left 5-spool control valve and right 4-
spool control valve
1) Remove oil pressure pickup plugs (4) and
(5) under the left 5-spool control valve and
oil pressure pickup plugs (6) and (7) under
the right 4-spool control valve.
• (4): High pressure side (Pt) of left 5-
spool control valve (F pump)
• (5): Low pressure side (Pd) of left 5-
spool control valve (F pump)
• (6): High pressure side (Pt) of right 4-
spool control valve (R pump)
• (7): Low pressure side (Pd) of right 4-
spool control valve (R pump) 3) Start the engine and set the working mode
a The jet sensor output differential pres- switch in the A-mode position.
sure may be measured at the inlet hose 4) Set all the control levers in neutral and
of the No. 1 pump by using adapter M4 measure the jet sensor output differential
and nipple M3. pressure under the following condition.
i) Set all the control levers in neutral.
ii) Run the engine at high idling and meas-
ure the output differential pressure.
a Jet sensor output differential pressure =
High pressure (Pt) – Low pressure (Pd)
5) Drive the travel motor idle and measure the
jet sensor output differential pressure under
the following condition.
i) Raise the track shoe to be measured by
using the boom and arm.
ii) Run the engine at high idling, drive the
travel motor idle, and measure the output
differential pressure.
a Jet sensor output differential pressure =
2) Install nipple [2] of hydraulic tester M1 and High pressure (Pt) – Low pressure (Pd)
connect it to differential pressure gauge M2
or oil pressure gauge [1].
a When using differential pressure gauge:
Connect the high pressure (Pt) to the
high pressure side (back side) of the dif-
ferential pressure gauge and connect
the low pressure (Pd) to the low pres-
sure side (lower side). Since the differ-
ential pressure gauge needs DC 12 V,
connect 1 battery to it.
a When using pressure gauge:
Connect the pressure gauge of 5.9 MPa
{60 kg/cm 2 } to the high pressure side
(Pt) and connect the pressure gauge of
2.5 MPa {25 kg/cm2} to the low pressure
side (Pd).
20-132 PC750, 800-7

(1)
1) Fix adjustment screw (9) and loosen locknut

(10).
2) Turn adjustment screw (9) to adjust the
pressure.
a If the adjustment screw is
es.
ers.
a Pressure changed by 1 turn of adjust-
ment screw: 0.34 MPa {3.5 kg/cm2}
3) Fix adjustment screw (9) and tighten locknut
3 Locknut:
(10).
6) After finishing measurement, remove the 5.9 – 9.8 Nm {0.6 – 1.0 kgm}
measuring instruments and return the
removed parts.
ADJUSTING
1. Adjusting TVC valve
a When adjusting the TVC valve, open the
pump compartment cover.
a If the TVC valve output pressure is abnor-
mal, adjust TVC valve (8) of the No. 1 pump
according to the following procedure.

2. Adjusting CO-NC valve

a When adjusting the CO valve side of the CO-
NC valve, remove the No. 1 pump undercov-
er. When adjusting the NC valve side, open
the pump compartment cover.
a If the CO-NC valve output pressure is abnor-
mal, adjust CO valves (11) and (12) and NC
valves (13) and (14) of the No. 1 pump ac-
cording to the following procedure.
• (11): Front CO valve of No. 1 pump
• (12): Rear CO valve of No. 1 pump
PC750, 800-7 20-133

(1)
• (13): Front NC valve of No. 1 pump 2) Adjusting NC valve side

• (14): Rear NC valve of No. 1 pump i) Fix adjustment screw (17) and loosen
locknut (18).
ii) Turn adjustment screw (17) to adjust the
pressure.
es.
ers.
iii) Fix adjustment screw (17) and tighten
3 Locknut:
locknut (18).
5.9 – 9.8 Nm {0.6 – 1.0 kgm}

1) Adjusting CO valve side
i) Fix adjustment screw (15) and loosen
locknut (16).
ii) Turn adjustment screw (15) to adjust the
pressure.
es.
ers.
iii) Fix adjustment screw (15) and tighten
3 Locknut:
locknut (16).
iv) After finishing adjustment, check the oil
5.9 – 9.8 Nm {0.6 – 1.0 kgm} pressure again according to the above
3. Adjusting jet sensors of left 5-spool control

valve and right 4-spool control valve
a If the jet sensor output differential pressure
of the left 5-spool control valve or right 4-
spool control valve is abnormal, adjust jet
sensor relief valves (19) and (20) according
• (19): Jet sensor relief valve of left 5-spool
control valve
• (20): Jet sensor relief valve of right 4-spool
control valve
iv) After finishing adjustment, check the oil

20-134 PC750, 800-7

(1)
1) Fix adjustment screw (21) and loosen lock-

nut (22).
2) Turn adjustment screw (21) to adjust the
pressure.
es.
ers.
3) Fix adjustment screw (21) and tighten lock-
3 Locknut: 59 – 78 Nm {6 – 8 kgm}
nut (22).

PC750, 800-7 20-135

(1)
TESTING AND ADJUSTING INSPECTION OF SERVO PISTON STROKE
INSPECTION OF SERVO PISTON STROKE

a Devices for inspecting and measuring piston a After checking that the rod moves
stroke control oil pressure smoothly, keep it at the position where it
is most protruded.
Symbol Part Number Part Name 5) Stop the engine and measure the size of the
708-25-14140 Cap rod protrusion a2.
1 6) Calculate the servo piston stroke b from the
N 07000-B2065 O-ring
measured size.
2 566-98-41120 Disc gauge a Servo piston stroke b = a2 – a1
a Standard stroke b: 9.37 mm
a When the NC valve output pressure is normal
but the pump performance is considered inap-
propriate, inspect the acceptability of the servo
valve and piston according to the following pro-
cedures:
1. Preparation of tool
Drill a through hole PT1/4 in the center of the
cap N1 and screw the disc gauge N2 in the hole.
a Prepare the cap for the side where the spring
of the hydraulic pump servo piston is fitted.
7) After finishing testing, remove the testing

tools and return the removed parts.
3. Judgment of servo valve

a If the servo piston stroke is abnormal, re-
move the servo valve, servo piston cap, and
spring, and check that you can move the ser-
vo piston smoothly before judging the condi-
tion of the servo valve.
1) When servo piston stroke is normal:
Servo valve is normal.
2. Measurement of stroke 2) When servo piston stroke is abnormal:
1) Remove the cap and the shim of the servo • Servo piston moves smoothly;
valve on the measuring side. Servo valve is abnormal.
a Since the cap is pressed with the spring, • Servo piston does not move smoothly;
remove the cap carefully with the long Servo valve is normal.
bolt (01016-31070, etc.) and the nut so
that the cap does not jump out.
2) Mount the measuring tools N, on the servo
piston together with the removed shim.
a Be careful so that the shim is not caught
in the bolt threads.
3) Push in the rods of the measuring tools, N,
fully and measure the size of the protrusion
a1.
4) Start the engine, keep it at full throttle and
move the track shoe without load or swing it
without load.
a Operate the lever to the full stroke.
a During the measurement, press the rod
with hand and check at the same time
that the rod moves smoothly as the con-
trol lever changes the stroke.
20-136 PC750, 800-7

(1)
TESTING AND ADJUSTING MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE

a Devices for measuring PPC valve output pres-
sure
1
P 790-261-1203 Digital hydraulic tester
2 799-401-3200 Adapter (Size: 03)
a Measure the PPC valve output pressure under

the following conditions:

range
stop the engine. Operate the control levers sev- 4. Run the engine at high idling, operate the con-
eral times to release the residual pressure in the trol lever of the PPC circuit to be measured, and
piping, and then loosen the oil filler cap of the measure the oil pressure.
hydraulic tank slowly to release the internal a Move the control lever to the stroke end.
pressure of the hydraulic tank. a Condition of actuator to be measured
• When measuring the pressure for the
1. Remove the control valve top cover. work equipment, move each cylinder to
the stroke end.
2. Disconnect hose (1) of the PPC circuit to be • When measuring the pressure for swing,
measured. Install adapter P2 and connect the turn the swing lock switch ON.
hose again. • When measuring the pressure for travel,
a For the hose to be disconnected, see the put pin [3] between the sprocket and
connection diagram on the next page. track frame to lock the track shoe.
3. Install nipple [1] of hydraulic tester P1 and con-

nect it to oil pressure gauge [2].
a Use a pressure gauge of 5.9 MPa {60 kg/cm2}
a The figure shows the measuring instruments
installed to the right travel (reverse) circuit of
the left 5-spool control valve.
5. After the measurement, remove the measuring

devices and return the valve to the original state.
PC750, 800-7 20-137

(1)
Connection diagram of pilot piping (PPC-Solenoid-OLSS circuit)
20-138 PC750, 800-7

(1)
a The colors in ( ) in the figure are the colors of the tapes wound onto the hoses.
PC750, 800-7 20-139

(1)
MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING
TESTING AND ADJUSTING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTOR VALVE
MEASURING OUTLET PRESSURES OF SOLENOID VALVE,

SWING PPC SHUTTLE VALVE, AND SWING PRIORITY
SELECTOR VALVE
a Devices for measuring outlet pressures of sole- • (2): Travel speed shifting solenoid valve
noid valve, swing PPC shuttle valve, and swing • (3): Machine push-up solenoid valve
priority selector valve • (4): 2-stage relief solenoid valve
• (5): Travel junction solenoid valve
Symbol Part Number Part Name • (6): CO cancel solenoid valve
1
2 799-401-3200 Adapter (Size: 03)
Q
3 799-401-3300 Adapter (Size: 04)
799-101-5220 Nipple (10 × 1.25 mm)
4
07002-11023 O-ring
a Measure the outlet pressures of solenoid valve,

swing PPC shuttle valve, and swing priority
selector valve under the following condition.

range
• (7): Swing holding brake solenoid valve
stop the engine. Operate the control levers sev-
eral times to release the residual pressure in the
piping, and then loosen the oil filler cap of the
hydraulic tank slowly to release the internal
pressure of the hydraulic tank.
1. Measuring outlet pressure of solenoid valve

1) Disconnect outlet hoses (1) – (8) of the sole-
noid valves to be measured. Install adapter
Q2 or Q3 and connect the hoses again.
a When measuring the safety lock sole-
noid valve, remove the operator's cab
undercover (the 2nd piece on the front
side).
a If the solenoid valve side of a hose is • (8): Swing priority solenoid valve
connected by a quick coupler, discon-
nect the other end of the hose (See the
connection diagram in MEASURING
PPC VALVE OUTPUT PRESSURE).
• (1): Safety lock solenoid valve
20-140 PC750, 800-7

(1)
2) Install the nipple (R1/8) of hydraulic tester

Q1 or nipple Q4 (10 × 1.25 mm) and con-
nect it to oil pressure gauge [1].
a Use a pressure gauge of 5.9 MPa {60
kg/cm2}
a The following figure shows the measur-
ing devices installed to the outlet hose of
the safety lock solenoid valve.
3) Run the engine at high idling, set the condi-

tion or operate the control levers as shown
in the table, and measure the output pres-
sure.
a When operating the work equipment-
swing or travel control lever, operate it
finely to a degree that the PPC oil pres-
sure switch is turned ON.
a If the solenoid valve outlet pressure is as
shown in the table, the solenoid valve is
normal.
4) After finishing measurement, remove the

removed parts.
PC750, 800-7 20-141

(1)
Measurement conditions for solenoid valve

a The measurement conditions in the following table are for measuring the solenoid valve outlet pressure and
they are a part of the operating condition of each solenoid valve.
Operation
Oil pressure
No. Solenoid valve Measurement condition Operation of machine of
(MPa {kg/cm2})
solenoid
• Set safety lock lever in LOCK Basic pressure circuit to
OFF 0 {0}
position. PPC valve is closed.
1 Safety lock
• Set safety lock lever in FREE Basic pressure circuit to Min. 2.74
ON
position. PPC valve is opened. {Min. 28}
• Set travel speed switch in Lo Swash plate angle of travel
OFF 0 {0}
position. motor is set to maximum.
2 Travel speed shifting
• Set travel speed switch in Hi Swash plate angle of travel Min. 2.74
ON
position. motor is set to minimum. {Min. 28}
• Turn machine push-up switch Boom LOWER safety valve
OFF 0 {0}
ON. is set to high pressure.
3 Machine push-up
• Turn machine push-up switch Boom LOWER safety valve Min. 2.74
ON
OFF. is set to low pressure. {Min. 28}
Main relief valve is set to low
• Turn heavy lift switch OFF. OFF 0 {0}
pressure.
4 2-stage relief • Turn heavy lift switch ON and
Main relief valve is set to Min. 2.74
raise boom singly. ON
high pressure. {Min. 28}
• Operate travel lever.
• Set all control levers in NEU- F pump circuit and R pump
OFF 0 {0}
TRAL position. circuit are separated.
5 Travel junction • Operate right and left travel
F pump circuit and R pump Min. 2.74
levers and work equipment- ON
circuit are merged. {Min. 28}
swing lever simultaneously.
• Set working mode switch in E-
Pump CO function is turned
mode. OFF 0 {0}
ON.
• Turn heavy lift switch OFF.
6 CO cancel • Set working mode switch in A-
mode. Pump CO function is turned Min. 2.74
ON
• Turn heavy lift switch ON. OFF. {Min. 28}
• Operate travel lever.
• Turn swing lock switch ON.
• Measure about 10 seconds
Swing holding brake is
after work equipment-swing OFF 0 {0}
applied.
control lever is set in NEU-
7 Swing holding brake TRAL position.
• Turn swing lock switch OFF
Swing holding brake is Min. 2.74
and operate work equipment- ON
released. {Min. 28}
swing control lever.
• Turn swing priority switch OFF Swing priority function is Min. 2.35
OFF
Swing priority and raise boom. turned OFF. {Min. 24}
8
(See note) • Turn swing priority switch ON Swing priority function is
ON 0 {0}
and raise boom. turned ON.
NOTE: The inlet pressure of the swing priority solenoid valve is the boom RAISE PPC circuit pressure.
Accordingly, when measuring the outlet pressure, move the boom control lever to the RAISE stroke end
(The boom cylinder may be at the RAISE stroke end).
20-142 PC750, 800-7

(1)
2. Measuring outlet pressure of swing PPC 3. Measuring outlet pressure of swing priority
shuttle valve selector valve
1) Disconnect outlet hose (9) of the swing PPC 1) Disconnect outlet hoses (10) and (11) of the
shuttle valve. Install adapter Q2 and con- swing priority selector valve. Install adapt-
nect the hose again. ers Q2 and connect the hoses again.
a When measuring the swing PPC shuttle a When measuring the swing priority se-
valve, remove the control valve top cover. lector valve, remove the control valve
top cover.
• (10): Port A1 (For swing)
• (11): Port A2 (For arm Lo and bucket Hi)
2) Install the nipple (R1/8) of hydraulic tester

Q1 and connect it to oil pressure gauge [1].
a Use a pressure gauge of 5.9 MPa {60
kg/cm2} 2) Install the nipple (R1/8) of hydraulic tester
3) Run the engine at high idling, set the condi- Q1 and connect it to oil pressure gauge [1].
tion or operate the control levers as shown a Use a pressure gauge of 58.8 MPa {600
in the table, and measure the output pres- kg/cm2}
k Since the outlet pressure of the swing

sure.
a If the swing PPC shuttle valve outlet
pressure is as shown in the table, the priority selector valve is the same as the
PPC shuttle valve is normal. main pump pressure, take care not to
connect the oil pressure gauge for low
Oil pressure
Measurement condition pressure.
(MPa {kg/cm2})
Neutral 0 {0}
Left work Position for Min. 2.35
equipment swinging to left {Min. 24}
control lever
Position for Min. 2.35
swinging to right {Min. 24}

removed parts.
PC750, 800-7 20-143

(1)
3) Run the engine at high idling, set the condi-

tion or operate the control levers as shown
in the table, and measure the output pres-
sure.
a If the swing priority selector valve outlet
pressure is as shown in the table, the
swing priority selector valve is normal.
• Port A1 (For swing)
Oil pressure
Measurement conditions
(MPa {kg/cm2})
Swing priority switch: OFF
Right work Neutral 0 {0}

equipment Position for Same as main
control lever raising boom pump pressure
Swing priority switch: ON
Right work Neutral 0 {0}

equipment Position for rais-
control lever ing boom 0 {0}
• Port A2 (For arm Hi and bucket Lo)

Oil pressure
Measurement conditions
(MPa {kg/cm2})
Neutral 0 {0}
Left work Position for Same as main
equipment swinging to left pump pressure
control lever
Position for Same as main
swinging to right pump pressure

removed parts.
20-144 PC750, 800-7

(1)
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE

a If there is excessive play at the tip of the work
equipment or swing lever, adjust at the PPC
valve end as follows.
• Standard lever play a: 0.5 – 3 mm at point 200
mm from rotating center of lever (forward and re-
verse, and left and right)
1. Remove boot (1).
2. Loosen locknut (2), then turn disc (3) to adjust

the play of the lever.
a When doing this, do not move the piston.
3. Secure disc (3) in position, then tighten locknut
3 Locknut :
(2) to the specified torque.
98.07 – 127.49 Nm {10 – 13 kgm}
4. Install boot (1).
PC750, 800-7 20-145

(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRAVEL DEVIATION
TESTING AND ADJUSTING TRAVEL DEVIATION

Measuring
a Measure on a hard and flat place.
1. Start the engine and set the work equipment in

the travel position.
a To set the work equipment in the travel posi-
tion, extend the bucket and arm cylinders ful-
ly and set the boom angle to 45 degrees.
2. Set the working mode switch to the A-mode

position and set the travel speed switch to the
Lo position.
3. Run up for 10 m with the engine speed at high

idling and continue travel under the same condi-
tion for 20 m and measure the deviation a.
a At this time, install an oil pressure gauge and
measure the pump discharge pressure, too,
(or monitor the pump discharge pressure
with the monitor panel).
20-146 PC750, 800-7

(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRAVEL DEVIATION
Adjusting • No. 1 pump

a If the travel deviation is abnormal, adjust the
thickness of the shim at the servo piston accord-
ing to the following procedure.
1. Determine where to add a shim from the direc-

tion of the travel deviation.
a Adjustment method
When machine When machine
deviates to left deviates to right
Add shim on front pump Add shim on rear pump
side (b). side (c).
• No. 1 pump
• No. 2 pump
• No. 2 pump
3. Add shim (2) according to the deviation and
tighten bolt (1).
a Limit the thickness of the added shim to 3
3 Bolt: 59 – 74 Nm {6.0 – 7.5 kgm}

mm for each pump.
a Travel deviation and thickness of added

shim
2. Loosen 4 bolts (1) on the side to adjust the shim.

a Since the shim is of split type, you do not
need to remove the cap.
a Since the cap is pressed by the spring, loos-
en the bolt to a degree that you can insert the
shim.
4. After finishing adjustment, check the travel devi-

ation again according to the above described
procedure.
PC750, 800-7 20-147

(1)
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK
TESTING AND ADJUSTING EQUIPMENT
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK

EQUIPMENT
a If there is any hydraulic drift in the work equip- 2. Inspection of arm cylinder
ment (cylinders), check in the following manner 1) Operate the arm cylinder to move the arm to
to determine if the cause is in the cylinder pack- the position 100 mm before the digging
ing or in the control valve. stroke end, and stop the engine.
1. Inspection of boom and bucket cylinders

1) Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
a Fill the bucket with earth or apply the rat-
ed load to the bucket.
2) Operate the arm control lever to move the

arm to the digging side.
• If the lowering speed increases, the cyl-
inder packing is defective.
• If there is no change, the control valve is
defective.
a Operate the control lever with the engine
2) Operate the control lever to the RAISE posi- starting switch in the ON position.
tion or the bucket control lever to the CURL a If pressure in the accumulator has
position. dropped, run the engine for approx. 10
• If the lowering speed increases, the cyl- seconds to charge the accumulator again.
inder packing is defective. [Reference]If the cause of the hydraulic drift is in the
• If there is no change, the control valve is defective packing, and the above opera-
defective. tion is carried out, downward movement
a Operate the control lever with the engine is accelerated for the following reasons.
starting switch in the ON position. 1) If the work equipment is set to the above pos-
a If pressure in the accumulator has ture (holding pressure applied to the bottom
dropped, run the engine for approx. 10 end), the oil at the bottom end leaks to the head
seconds to charge the accumulator end. However, the volume at the head end is
again. small than the volume at the bottom end by the
volume of the rod end, so the internal pressure
at the head end increases because of the oil
flowing in from the bottom end.
2) When the internal pressure at the head end
increases, the pressure at the bottom end also
rises in proportion to this. The balance is main-
tained at a certain pressure (this differs accord-
ing to the amount of leakage) by repeating this
procedure.
3) When the pressure is balanced, the downward
movement becomes slower. If the lever is then
operated according to the procedure given
above, the circuit at the head end is opened to
the drain circuit (the bottom end is closed by the
check valve), so the oil at the head end flows to
the drain circuit and the downward movement
becomes faster.
20-148 PC750, 800-7

(1)
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE

a Measuring device for oil leakage 2. Measuring leakage from arm cylinder
1) Run the engine and move in the arm to the
Symbol Part Number Part Name stroke end.
k Referring to RELEASE OF RESIDUAL

R Purchased Measuring cylinder
a Measure the oil leakage under the following PRESSURE FROM HYDRAULIC CIR-
condition. CUIT, release the residual pressure
• Hydraulic oil temperature: Within operating from the piping on the arm cylinder
range head side (Operate the lever only in the
IN direction, however).
1. Measuring leakage from boom cylinder 2) Disconnect hose (2) on the cylinder head
1) Run the engine and raise the boom to the side and block it with a flange.
k Take care not to disconnect the hose on

stroke end.
k Referring to RELEASE OF RESIDUAL the cylinder bottom side.

PRESSURE FROM HYDRAULIC CIR- a Use the following part to block the hose.
CUIT, release the residual pressure 07379-01470 (Flange #14)
from the piping on the boom cylinder
head side (Operate the lever only in the
RAISE direction, however).
2) Disconnect hoses (1) on the cylinder head
side and block it with a flange.

the cylinder bottom side.
a Use the following part to block the hose.
07379-01260 (Flange #12)
3) Run the engine at high idling and relieve the

arm cylinder by operating the arm control
lever in the IN direction.
k Take care not to operate the arm con-

trol lever in the OUT direction.
4) Start measuring the oil leakage 30 seconds
after the arm cylinder is relieved and meas-
ure for 1 minute.
5) After finishing measurement, return the
3) Run the engine at high idling and relieve the parts.
boom cylinder by operating the boom con-
trol lever in the RAISE direction.
k Take care not to operate the boom con-

trol lever in the LOWER direction.
4) Start measuring the oil leakage 30 seconds
after the boom cylinder is relieved and
measure for 1 minute.
parts.
PC750, 800-7 20-149

(1)
3. Measuring leakage from bucket cylinder 4. Measuring leakage from swing motor
1) Run the engine and curl the bucket to the 1) Disconnect drain hoses (4) and (5) and plug
stroke end. them.
k Referring to RELEASE OF RESIDUAL

a Use the following parts to block the hos-
es.
PRESSURE FROM HYDRAULIC CIR- 07376-70522 (Plug #05)
CUIT, release the residual pressure • (4): Drain hose of front swing motor
from the piping on the bucket cylinder
head side (Operate the lever only in the
CURL direction, however).
2) Disconnect hose (3) on the cylinder head
side and block it with a flange.

the cylinder bottom side.
07379-01470 (Flange #14)
• (5): Drain hose of rear swing motor

bucket cylinder by operating the bucket con-
trol lever in the CURL direction.
k Take care not to operate the bucket

control lever in the DUMP direction. 2) Turn the swing lock switch ON.
4) Start measuring the oil leakage 30 seconds 3) Run the engine at high idling and relieve the
after the bucket cylinder is relieved and swing circuit and measure the oil leakage.
measure for 1 minute. a Start measuring the oil leakage 30 sec-
5) After finishing measurement, return the onds after the swing motor circuit is re-
parts. lieved and measure for 1 minute.
a After measuring 1 time, swing the upper
structure 180° and measure again.
parts.
20-150 PC750, 800-7

(1)
5. Measuring leakage from travel motor 6. Measuring leakage from center swivel joint
1) Remove the travel motor cover. 1) Put block [1] between the sprocket and
4 Travel motor cover: 120 kg

frame to lock the travel motor of the port to
be inspected, and then stop the engine.
k Loosen the oil filler cap of the hydraulic

2) Start the engine and lock the travel mecha-
nism.
k Set pin [1] between the sprocket and

tank slowly to release the internal pres-
sure of the tank.
track frame to lock the travel mecha- a Inspection ports, travel directions, and
nism securely. measurement ports (See figure on fol-
lowing parts)
Inspection Travel Measurement
port direction ports
A Right reverse T and B
B Right forward A and P
Change of
P B and C
speed
C Left reverse P and D
D Left forward C and T
T Drain
3) Disconnect drain hose (6) of the travel

motor and plug it.
07376-70522 (Plug #05)

travel circuit and measure the oil leakage.
k Since wrong operation of the levers can

cause an accident, make signs and
confirmation securely.
a Start measuring the oil leakage 30 sec-
onds after the travel motor circuit is re-
lieved and measure for 1 minute.
a Measure the oil leakage several times,
moving the motor little by little (changing
the positions of the valve plate and cylin-
der and those of the cylinder and piston).
parts.
PC750, 800-7 20-151

(1)
2) Disconnect the hoses of the upper and 3) Run the engine at high idling and measure
lower measurement ports of the inspection the oil leakage through the measurement
port from the top of the swivel joint and ports.
block them. a When measuring ports A, B, C, and D,
a For combination of the inspection port relieve the travel motor slowly in the re-
and measurement ports, see the above volving direction (See the table on the
table. last page).
a Use the following parts to block the hos- a When measuring port P, set the travel
es. speed shifting switch in the Hi position.
• Ports A, B, C, and D: 07379-01044 4) Start measuring the oil leakage 1 minute
(Flange #10) after the center swivel joint is relieved and
• Port P: 07376-70315 (Plug #03) measure for 1 minute.
• Port T: 07376-70522 (Plug #05)
20-152 PC750, 800-7

(1)
TESTING AND ADJUSTING RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT
RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT

1. Release of residual pressure from hydraulic 3. Release of residual pressure from swing mo-
tank tor circuit
k The hydraulic tank is enclosed and pressu-

a Release the residual pressure from the
swing motor circuit by performing the proce-
rized. When removing a hose or a plug con- dure for 2. Release of residual pressure from
nected to the hydraulic tank, release the hydraulic cylinder circuit.
residual pressure from the hydraulic tank
according to the following procedure. 4. Release of residual pressure from travel mo-
1) Lower the work equipment to the ground in tor circuit
a stable posture and stop the engine. a Since the control valve spool of the travel
2) Slowly loosen oil filler cap (1) of the hydrau- motor is open, release the residual pressure
lic tank to release the air from the tank. from the travel motor circuit by performing
the procedure for 1. Release of residual
pressure from hydraulic tank.
2. Release of residual pressure from hydraulic

cylinder circuit
k When disconnecting the piping between a

hydraulic cylinder and the control valve, re-
lease the residual pressure from the piping
according to the following procedure.
1) Referring to 1. Release of residual pressure
from hydraulic tank, release the residual
pressure from the hydraulic tank.
a Leave the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch to the ON position
and set the safety lock lever in the FREE
position, and then operate the work equip-
ment control levers on both sides forward,
backward, to the right, and to the left.
a The control valve is driven with the pres-
sure in the accumulator. If it is operated
2 – 3 times, the pressure lowers.
3) Start the engine and run it at low idling for 5
seconds to heighten the pressure in the
accumulator.
4) Repeat above steps 2) and 3) 2 – 3 times,
and all residual pressure is released from
the piping.
PC750, 800-7 20-153

(1)
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
BLEEDING AIR FROM EACH PART
Air bleeding item Air bleeding procedure

1 2 3 4 5 6
Bleeding Bleeding Bleeding Checking
Bleeding
air from Starting air from air from oil level
air from
hydraulic engine swing travel and start-
cylinder
Contents of work pump motor motor ing work
• Replacement of hydraulic oil q q
q q q q
• Cleaning of strainer (See note) (See note)
• Replacement of return filter ele-
q q
ment
• Replacement or repair of
hydraulic pump q q q q
• Removal of suction piping
• Replacement or repair of control
valve q q q
• Removal of control valve piping
• Replacement or repair of cylin-
der q q q
• Removal of cylinder piping
• Replacement or repair of swing
motor q q q
• Removal of swing motor piping
• Replacement or repair of travel
motor q q q
• Removal of travel motor piping
• Replacement or repair of swivel
joint q q
• Removal of swivel joint piping
NOTE: Bleed air from the swing motor and travel motor only when the oil was drained from the motor cases.
1. Bleeding air from hydraulic pump 3) After clear oil flows out of bleeders (1) and
3 Bleeder:
1) Loosen air bleeders (1) and (2) by 4 turns (2), tighten the bleeders.
and remove the oil filler cap of the hydraulic
tank. 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
a Leave the machine under the above
condition for 10 minutes or more.
2) After oil flows out of bleeders (1) and (2),
run the engine at low idling.
a If the engine water temperature is low
and the automatic warm-up operation is
started, stop the engine temporarily and
reset the automatic warm-up operation
with the fuel control dial (Set the starting
switch in the ON position and hold the
fuel control dial in the MAX position for 3
seconds, and the automatic warm-up
operation is reset).
a Set the safety lock lever in the LOCK po-
sition so that you will not operate a lever
by mistake.
20-154 PC750, 800-7

(1)
2. Starting engine • Front swing motor

When running the engine after performing step
1, keep its speed at low idling for 10 minutes.
3. Bleeding air from cylinder

a If a cylinder was replaced, bleed air from it
before connecting the work equipment. In
particular, the boom cylinder does not move
to the lowering stroke end, if it is installed to
the work equipment.
1) Run the engine at low idling for about 5 min-
utes.
2) Running the engine at low idling, raise and
lower the boom 4 - 5 times.
a Stop the piston rod about 100 mm before
each stroke end. Do not relieve the oil. • Rear swing motor
3) Running the engine at high idling, perform
step 2).
4) Running the engine at low idling, move the
piston rod to the stroke end and relieve the
oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) – 4).
4. Bleeding air from swing motor

1) Motor unit
a Bleed air from the motor unit according
i) Run the engine at low idling.
ii) Swing to the right and left slowly to bleed
air. 3) Safety valve circuit
2) Parking brake circuit a Normally, air in the safety valve circuit is
a Normally, air in the parking brake circuit bled by swinging the machine in step 1).
is bled by swinging the machine in step If abnormal sound comes out from
1). If you feel dragging of the brake dur- around the safety valve during swinging
ing swinging operation, however, bleed operation, however, bleed air from the
air from the parking brake circuit accord- safety valve circuit according to the fol-
ing to the following procedure. lowing procedure.
i) Loosen the adapters of brake hoses (3) i) Loosen plugs (5) and (6) and start the
and (4) and start the engine. engine.
ii) Run the engine at low idling and set the ii) Run the engine at low idling. After clear
swing holding brake release switch to the
3 Plug:
oil oozes out, tighten the plugs.
RELEASE and NORMAL positions
repeatedly. After clear oil oozes out, 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
tighten the adapters.
PC750, 800-7 20-155

(1)
5. Bleeding air from travel motor

1) Remove the travel motor cover.
4 Travel motor cover: 120 kg

2) Loosen bleeder (7) by 1 turn and start the
engine.
a Do not loosen the bleeder more than 1
turn.
3) Run the engine at low idling and repeat the
forward and reverse travel operations 4 - 5
times. After clear oil flows out, tighten the
bleeder.
a Limit the operation of the lever to a de-
3 Bleeder:
gree that the machine starts traveling.
9.8 – 12.74 Nm {1.0 – 1.3 kgm}
6. Checking oil level and starting work

1) Run the engine, retract the arm cylinder and
bucket cylinder to the stroke ends, lower the
work equipment to the ground, and stop the
engine.
2) Check the oil level by the sight gauge at the

back of the hydraulic tank.
a If the oil level is between lines H and L, it
is normal.
a If the oil level is below line L, add new oil.
20-156 PC750, 800-7

(1)
TESTING AND ADJUSTING INSPECTION PROCEDURES FOR DIODE
INSPECTION PROCEDURES FOR DIODE

a Check an assembled-type diode (8 pins) and 3) Determine if a specific diode is good or no
single diode (2 pins) in the following manner. good with the indicated value.
a The continuity direction of an assembled-type • No change in the indicated value: No
diode is as shown in the diagram below. continuity (defective).
• Change in the indicated value: Continui-
ty established (normal) (Note)
Note: A silicon diode shows a value between
400 and 600.
a The continuity direction of a single diode is

shown on the diode surface.
2. When using analog type circuit tester

1) Switch the testing mode to resistance range.
2) Check the needle swing in case of the fol-
lowing connections.
i) Put the red probe (+) of the test lead to
the anode (P) and the black probe (–) to
the cathode (N) of diode.
ii) Put the red probe (+) of the test lead to
the cathode (N) and the black probe (–)
to the anode of diode.
3) Determine if a specific diode is good or no
good by the way the needle swings.
1. When using digital type circuit tester • If the needle does not swing in Case i),
1) Switch the testing mode to diode range and but swings in Case ii): Normal (but the
confirm the indicated value. breadth of swing (i.e. resistance value)
a Voltage of the battery inside is displayed will differ depending on a circuit tester
with conventional circuit testers. type or a selected measurement range)
2) Put the red probe (+) of the test lead to the • If the needle swings in either case of i)
anode (P) and the black probe (–) to the and ii): Defective (short-circuited inter-
cathode (N) of diode, and confirm the dis- nally)
played value. • If the needle does not swing in any case
of i) and ii): Defective (short-circuited in-
ternally)
PC750, 800-7 20-157

(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
SPECIAL FUNCTION OF MONITOR PANEL
[1] Figure input switch 1 [6] Figure input switch 6 [ ] Return switch
[2] Figure input switch 2 [7] Figure input switch 7 [ ] Upward move switch
[3] Figure input switch 3 [8] Figure input switch 8 [ ] Downward move switch
[4] Figure input switch 4 [9] Figure input switch 9 [ ] Input confirmation switch
[5] Figure input switch 5 [0] Figure input switch 0
20-158 PC750, 800-7

(1)
Monitor panel functions - conventional and special

The monitor panel is provided with conventional and special functions, and various kind of information are
shown in the display. Display items consists of automatic display items that are preset in the monitor panel and
others that are shown by switch operations.
1. Conventional function: Operator's Menu

This is a function by which an operator can set or show displays by switch operations. The display contents
are those which are normally shown.
2. Special function: Service Menu

This is a function by which a service mechanic can set or show displays by special switch operations. The
display contents are those which are not normally shown. It is mainly used for inspection, adjustment, trou-
bleshooting or special setting of machines.
Operator's Menu Service Menu

1 Function for showing KOMATSU logo 14 Function for monitoring [01]
2 Function for check before starting Function for failure Electrical system
15
3 Function for showing machine maintenance history [02] Mechanical system
4 Function for showing caution items 16 Function for maintenance history [03]
Function for confirming working mode and travel 17 Function for maintenance mode change [04]
5
speed
18 Function for recording phone No. [05]
6 Function for display of ordinary items
Mode with key on
Function for adjusting display luminance and con-
7 Function for initial value Language
trast 19
setting and default [06] Unit
8 Function for confirming maintenance information
Wiper select
9 Function for showing service meter reading
20 Function for adjustment [07]
10 Function for checking display LCD
21 Function for reduced cylinder mode operation [08]
11 Function for showing occurrence of caution item
12 Function for showing users' code No.
Function for showing error code No. and failure
13
code No.
PC750, 800-7 20-159

(2)
Operation of Operator's Menu and

Display (Outline)
a This section introduces only the outline of the
operator's menu. For details on the contents and
operation steps of each menu, refer to the oper-
ation and maintenance manual or the chapter of
"STRUCTURE AND FUNCTION" in this shop
manual.
1. Function for showing KOMATSU logo

When the engine starting switch is turned ON,
KOMATSU logo is shown for two seconds.
2. Function for machine inspection before start-

ing day's work
Following the KOMATSU logo, the display of
machine inspection before starting day's work is
shown for 2 seconds.
3. Function for machine maintenance

Following the display of machine inspection
before starting day's work, the maintenance
mark appears for 30 seconds, if there is an oil fil-
ter whose maintenance time is approaching or
has just passed.
a This display appears only when the mainte-
nance function is set.
4. Function for showing precaution items

If there is any item of machine inspection before
starting day's work that indicates some abnor-
mality, a corresponding symbol mark is shown
after the display of machine inspection before
starting day's work.
20-160 PC750, 800-7

(1)
5. Function for confirming working mode and

travel speed
After the display of machine inspection before
day's work, amplified symbol marks for working
mode and travel speed are shown for 2 seconds
to urge an operator to confirm the setting.
6. Function for display of ordinary items

The display of confirming working mode and
travel speed is switched to this display of ordi-
nary items.
a If the working mode setting or travel speed
setting is changed, or auto-deceleration or
windshield wiper setting is activated while
this is in display, an amplified corresponding
symbol mark is shown for 2 seconds.
a In this display, a symbol mark for preheat
monitor is shown only when preheating is
carried out.
7. Function for adjusting display luminance and

contrast
Luminance as well as contrast of the display can
be adjusted by operating the display adjusting
switch.
8. Function for confirming maintenance infor-

mation
Detailed information on maintenance items (set
time and elapse of time) can be confirmed and
resetting after the confirmation is feasible by
operating the maintenance switch.
a Use Service Menu for setting or releasing
maintenance items and setting maintenance
time.
PC750, 800-7 20-161

(1)
9. Function for showing service meter reading

Only the service meter reading can be shown by
the following switching operation, when the
engine starting switch is turned OFF.
• Switching operation: [ ] + [ ] (synchro-
nized switching operation)
10. Function for checking display LCD

Display of the Display LCD can be confirmed by
the following switching operation in the display
of ordinary items
• Switching operation: [ ] + [A] (synchro-
nized switching operation)
a All the LCD light up, turning the entire screen
white. If there is no showing in black, the dis-
play is normal.
a This display returns to the immediately pre-
ceding one, if making any other switching
operation.
11. Function for showing occurrence of caution

item
If any of the caution items occurs, the magnified
corresponding symbol mark is shown for 2 sec-
onds and thereafter stays on the display as a
small symbol mark until it is dissolved.
12. Function for showing users' code No.

When a trouble occurs on the machine, the
user's code is automatically displayed depend-
ing on the magnitude of the trouble to call atten-
tion of the operator for a proper action.
a This display turns to the display of error code
and failure code, if operating the switch (Re-
fer to Item No. 13)
20-162 PC750, 800-7

(1)
a User codes and instructions given to operator

User
Failure mode Instructions given to operator
code
If the emergency pump drive switch is set to the upper (emergency) position,
E02 Error in pump control system the machine can operate normally. Have the machine inspected immediately,
however.
Set the swing holding brake release switch to the upper (release) position to
release the brake. When applying the swing brake, use the swing lock
E03 Error in swing brake system
switch. The error may not be reset, depending on the cause of the failure.
In any case, have the machine inspected immediately.
Error in engine controller power
supply system
E10 Have the machine inspected immediately.
Abnormality in engine controller
drive system circuit (engine stop)
Error in engine controller system Set the machine in a safe position and have the machine inspected immedi-
E11
(Engine protection output down) ately.
Set the machine in a safe position and have the machine inspected immedi-
E14 Error is throttle system
ately.
Error in engine sensor
Ordinary operation is possible. Have the machine inspected immediately,
E15 (water temperature, fuel tempera-
however.
ture and oil pressure)
Set the machine in a safe position and have the machine inspected immedi-
E0E Error in network
ately.
PC750, 800-7 20-163

(1)
13. Function for showing error code No. and fail-

ure code No.
If the following switching operation is made
while the users' code No. is shown, a phone
symbol (if registered), phone numbers (if regis-
tered), error code No. and failure code No. are
shown in turn.
• Switching operation: [ ]
a The following display is repeated in order ac-
cording to the operation of the switch.
[1] Telephone symbol mark
[2] Telephone No.
[3] Error code No. and failure code No.

a The telephone symbol mark and telephone
No. are shown only when they are registered
in the monitor panel.
For registration, correction and deletion of
telephone No., use Service Menu.
a For details on the displayed error code No.
and failure code No., refer to the Table for
Error and Failure Code Nos.
20-164 PC750, 800-7

(1)
Table for Error and Failure Code Nos.

Error code Failure code
division
History
code
User
Code Contents Code Component Trouble

— E112 Wiper Drive (For) S/C DY2DKB Wiper motor (Forward) Short circuit
— E113 Wiper Drive (Rev) S/C DY2EKB Wiper motor (Reverse) Short circuit
Windshield washer
— E114 Washer Drive S/C DY2CKB Short circuit
motor
— E115 Wiper Working Abnormality DY20KA Wiper motor Disconnection
— E116 Wiper Parking Abnormality DY20MA Wiper motor Malfunction
Communication trouble
— E117 Eng. Controller S-NET Comm Err. DAC0KR Engine controller (Abnormality in objective
component system)
Communication trouble
— E118 Pump Controler S-NET Comm Err. DAB0KR Pump controller (Abnormality in objective
component system)
Monitor CAN communi-
E0E E128 Monitor Comm. Abnormality DAFRMC Defective operation
cation
Cut-off cancel solenoid
— E201 CO Cancel Sol. S/C DW48KB Short circuit
valve
Travel neutral solenoid
— E202 Travel Junction Sol. S/C DW91KB Short circuit
valve
Swing holding brake
E03 E203 Swing Brake Sol. S/C DW45KB Short circuit
solenoid valve
2-stage relief solenoid
— E204 2-stage Relief Sol. S/C DWK0KB Short circuit
valve
Electrical system
— E205 Swing Priority Sol. S/C DW41KB Swing solenoid valve Short circuit
Travel high-low selector
— E206 Travel Speed Sol. S/C DW43KB Short circuit
solenoid valve
— E207 Flash Light Relay S/C D163KB Flash light drive relay Short circuit
Cut-off cancel solenoid
— E211 CO Cancel Sol. Disc. DW48KA Disconnection
valve
Travel neutral solenoid
— E212 Travel Junction Sol. Disc. DW91KA Disconnection
valve
Swing holding brake
E03 E213 Swing Brake Sol. Disc. DW45KA Disconnection
solenoid valve
2-stage relief solenoid
— E214 2-stage Relief Sol. Disc. DWK0KA Disconnection
valve
— E215 Swing Priority Sol. Disc. DW41KA Swing solenoid valve Disconnection
Travel high-low selector
— E216 Travel Speed Sol. Disc. DW43KA Disconnection
solenoid valve
Pump controller model Disagreement of model
— E217 Model selection Abnormality DA2SKQ
selection wiring harness selection signals
Pump controller S-NET
E0E E218 S-Net Comm. Disc. DA2SKA Disconnection
communication
— E221 Travel Alarm S/C DV20KB Backup alarm buzzer Short circuit
Front pump pressure
— E224 F Pump P. Sensor Abnormality DHPAMA Malfunction
sensor
Rear pump pressure
— E225 R Pump P. Sensor Abnormality DHPBMA Malfunction
sensor
Output of pump control- Lowering of output
— E226 Press. Sensor Power Abnormality DA25KP
ler power supply voltage
PC750, 800-7 20-165

(1)
division
History
code
User

— E227 Engine Speed Sensor Abnormality DLE2MA Engine speed sensor Malfunction
E02 E232 TVC Sol. S/C DXA0KB TVC solenoid valve Short circuit
E02 E233 TVC Sol. Disc. DXA0KA TVC solenoid valve Disconnection
Pump controller CAN
E0E E257 Pump Comm. Abnormality DA2RMC Defective operation
communication
— E302 Step Light Relay S/C D195KB Step light drive relay Short circuit
Step light power source
— E304 Step Light Power Hold Relay S/C D194KB Short circuit
holding relay
— E315 Battery Relay Drive S/C D110KB Battery relay Short circuit
Disagreement of speed
E11 E91B Engine Ne sensor problem DLE3LC Ne speed sensor
signals
Disagreement of speed
E11 E91C Engine G sensor problem DLH1LC G speed sensor
signals
Engine controller model Disagreement of model
E11 E920 Engine type selection error DB29KQ
selection wiring harness selection signals
Disagreement of model
E11 E921 Engine type mismatch DB20KQ Engine controller
selection signals
E14 E931 Fuel dial sys. error DK10KX Throttle angle sensor Out of input signal range
Engine water tempera-
E15 E934 Engine coolant sensor Hi error DGE2KX Out of input signal range
ture sensor
Engine oil pressure Disagreement of signals
E15 E936 Engine oil press. sw. error DDE2L6
switch and run/stop of engine
Electrical system
E11 E93C Engine boost sensor error DH30KX Boost pressure sensor Out of input signal range
E15 E93D Engine fuel temp. sensor error DGE4KX Fuel temperature sensor Out of input signal range
Engine controller CAN
E0E E953 Engine Comm. Abnormality DB2RMC Defective operation
communication
— E954 Short engine starter sw. DD11KB Starting switch Short circuit
Engine controller S-NET
E0E E955 Engine S-NET error DB2SMC Defective operation
communication
Engine controller load Lowering of source
E10 E956 Engine power failure (1) DB22KK
power source line voltage (Input)
Engine controller load
E15 E957 Engine power failure (2) D1D0KB Short circuit
power source relay
Rotary switch in engine
— E95A Engine Q-adj. sw. signal error DB2AMA Malfunction
controller
Engine water tempera- Disagreement of signals
E15 E96A Engine coolant sensor Lo error DGE3L6
ture sensor 2 and run/stop of engine
Supply pump (1)
E11 E970 PCV1 over current AD11KB Short circuit
solenoid valve
Supply pump (2)
E11 E971 PCV2 over current AD51KB Short circuit
solenoid valve
Supply pump (1)
E11 E974 PCV1 line cut AD11KA Disconnection
solenoid valve
Supply pump (2)
E11 E975 PCV2 line cut AD51KA Disconnection
solenoid valve
Common rail fuel
E11 E977 Rail press. sensor error DH40KX Out of input signal range
pressure sensor
E11 E979 Rail press. high AD00L2 Common rail Fuel pressure is too high
20-166 PC750, 800-7

(1)
division
History
code
User

E11 E97A Rail press. abnormal AD00MA Common rail Malfunction
E15 E97B Rail press. low AD10L3 Supply pump Uncontrollability
E11 E97C Rail press. too low AD10MB Supply pump Lowering of function
E11 E97D Rail press.out of control AD10MA Supply pump Malfunction
E10
or E980 Eng. Controller Abnormality DB20KT Engine controller Abnormality in controller
E11
Electrical system
E11 E981 Fuel Injector 1 Disc. ADA1KA Injector 1 solenoid valve Disconnection
E11 E982 Fuel Injector 2 Disc. ADB1KA Injector 2 solenoid valve Disconnection
E11 E983 Fuel Injector 3 Disc. ADC1KA Injector 3 solenoid valve Disconnection
E11 E984 Fuel Injector 4 Disc. ADD1KA Injector 4 solenoid valve Disconnection
E11 E985 Fuel Injector 5 Disc. ADE1KA Injector 5 solenoid valve Disconnection
E11 E986 Fuel Injector 6 Disc. ADF1KA Injector 6 solenoid valve Disconnection
Injector 1, 2, 3 solenoid
E11 E98A Fuel Injector 1 – 3 S/C ADAZKB Short circuit
valve
Injector 4, 5, 6 solenoid
E11 E98B Fuel Injector 4 – 6 S/C ADDZKB Short circuit
valve
— None Eng. Lo Out of Std A000KX Engine Out of input signal range
— None Eng. Hi Out of Std A000N1 Engine Overrun
— None Aircleaner Clogging AA10NX Air cleaner element Clogging
Mechanical system
— None Charge Voltage Low AB00KE Alternator Defective charge
E11 E924 Eng. Oil Press. Low B@BAZG Engine oil Lowering of oil pressure
— None Eng. Oil Level Low B@BAZK Engine oil Lowering of level
— None Eng. Water Overheat B@BCNS Cooling water Overheating
— None Eng. Water Lvl Low B@BCZK Cooling water Lowering of level
— None Hydr. Oil Overheat B@HANS Hydraulic oil Overheating
— None Auto. Lub. Abnormal. DA80MA Auto grease controller Malfunction
a The items in this list are arranged in the order of the error codes.
a The error codes having no numbers in the user code column and the failure codes having no numbers in
the user code column and error code column are not displayed on the normal screen, even if abnormality
related to them occurs. They are simply recorded in the failure history of the service menu (Electrical sys-
tem or mechanical system).
a The history division column shows in which division each failure is classified, the electrical system or
mechanical system, when it is recorded in the failure history.
a In "Error code: E924/Failure code: B@BAZG", the error code is displayed only when the user code is
turned ON and the failure code is recorded in only the mechanical system of the failure history.
a Letter "E" at the head of each error code indicates the following condition.
• With E: The failure has not been repaired yet.
• Without E: The failure has been repaired.
PC750, 800-7 20-167

(1)
Operation and Display of Service Menu
Way of switching to Service Menu

a When using Service Menu, change the display
to Service Menu display through the following
special operation.
1) Confirmation of display
Confirm that the display of ordinary items is
shown.
a Changing to Service Menu cannot be made
from displays other than this.
2) Switch operation
Operate the switch as instructed below.
• Switch operation: [ ] + [1] o [2] o [3]
(Enter a figure, depressing [ ])
3) Showing Service Menu display

The display is changed to the initial display of
Service Menu program. Select an appropriate
item from among the menu.
No. Service Menu
00 Return (Termination of Service Menu)
01 Monitoring
02 Abnormality Record
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
06 AAAAA / Default
07 Adjustment
08 Cylinder cut out
4) Termination of Service Menu function

When terminating the initial display or any sub-
sequent display of Service Menu, do that
through any one of the following methods.
[1] Depress [ ] switch. (This method may be
used for terminating any display)
[2] If "Return" switch is shown, depress it.
[3] If "Return" menu is shown, call that menu
and depress [ ] switch.
20-168 PC750, 800-7

(2)
14. Function of Monitoring [01]

The monitor panel monitors signals from an
assortment of switches, sensors and actuators
installed in various parts of the machine. Moni-
tored information can be put in display or con-
firmed on a real time basis through the following
operations.
1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.
2) Setting of monitoring item

Select or register an item to be monitored
through the following switch operation.
• [ ] switch: Selection
• [ ] switch: Selection
• [ ] switch: Registration
a A monitoring item can be set in any number
between the min. one to the max. four. (De-
pending upon the selected item, the max.
number is less than four)
a In case of monitoring 1 to 3 items, move to
the monitored information display through
any of the following switch operations, after
the registration work has been completed.
• Keep [ ] switch depressed. (For about
3 seconds)
• Select Menu 99999 and depress [ ]
switch.
a The display automatically moves to the dis-
play of monitored information, when all of the
registrable items have been duly registered.
a Monitored information are transmitted via
communication circuits. Thus the number of
selected items can impact the communica-
tion speed. If truly real time monitoring is re-
quired, reduce the selected items to the
minimum.
a For details on the monitoring items, display
unit, etc., refer to the Table for Monitoring
Items.
PC750, 800-7 20-169

(1)
3) Monitoring operation
Call the monitoring information display and
confirm the monitored information, while
operating the machine.
4) Monitored information holding function

If [ ] switch is depressed while monitoring,
all the monitored information are put on
hold. If [ ] switch is depressed in this con-
dition, information holding is released.
5) Machine setting mode switching function

If it becomes necessary to change settings
of working mode, travel speed and auto-
decel while monitoring, depress the corre-
sponding switch, then the mode confirma-
tion display is shown.
a When a specific setting is confirmed, de-
press [ ] switch, then the display re-
turns to that of monitoring.
a In case a specific setting has been
changed while monitoring, the new set-
ting is still maintained when returning
from Service Menu to Operator's Menu
after the monitoring is finished.
20-170 PC750, 800-7

(1)
Monitoring items list
Code Unit (Default: SI)

Monitoring item Remarks
No. SI meter inch
00000 Return (Not displayed) Finish menu
99999 Display and execution (Not displayed) Display and execution menu
00200 Controller Model Select Numeral
00201 Controller Model Select Numeral
01002 Engine Speed r/min rpm rpm
01601 2nd Eng. Speed Command r/min rpm rpm
01100 F Pump Pressure MPa kg/cm2 psi
01101 R Pump Pressure MPa kg/cm 2
psi
04102 Engine Water Temp. Hi °C °C °F
14200 Fuel Temperature °C °C °F
04401 Hydr. Oil Temperature °C °C °F
01300 TVC Sol. Curr. mA mA mA
03200 Battery Voltage V V V
03500 Battery Relay O/P Vol. V V V
04300 Battery Charge Vol. V V V
01006 Engine Speed r/min rpm rpm
04107 Engine Water Temp. Low °C °C °F
36400 Rail Pressure MPa kg/cm2 psi
36500 Boost Pressure kPa kg/cm2 psi
36700 Torque Ratio % % %
03000 Fuel Dial Vol. V V V
04200 Fuel Level Sensor Vol. V V V
04106 Eng. Water Temp. Vol. Hi V V V
04105 Eng. Water Temp. Vol. Lo V V V
14201 Fuel Temp. Sensor Vol. V V V
36501 Boost Press. Sensor Vol. V V V
36401 Rail Press. Sensor Vol. V V V
17200 PCV Close Angle CA CA CA
17300 Eng. Controll Mode Numeral
31701 Throttle Level % % %
36100 Fuel Delivery Command mm3/st mm3/st mm3/st
36200 Rail Pressure Command MPa kg/cm2 psi
36300 Injection Timing Angle CA CA CA
37300 Fuel Consumption Rate L/h L/h L/h
14300 Fuel Consumption L L L
PC750, 800-7 20-171

(1)

No. SI meter inch
Swing ON/OFF
R.H Travel ON/OFF
Boom Lower ON/OFF
01900 Pressur Switch 1
Boom Raise ON/OFF
Arm Curl ON/OFF
Arm Dump ON/OFF
Bucket Curl ON/OFF
Bucket Dump ON/OFF
01901 Pressur Switch 2
Service ON/OFF
L.H Travel ON/OFF
Travel Junction ON/OFF
Swing Brake ON/OFF
2-Stage Relief ON/OFF
02300 Solenoid Valve 1
Travel Speed ON/OFF
CO Cancel ON/OFF
Swing Priority ON/OFF
Lever Sw. ON/OFF
02200 Switch Input 1 Swing Release Sw ON/OFF
Swing Brake Sw. ON/OFF
Model Select 1 ON/OFF
02201 Switch Input 2
— ON/OFF
02202 Switch Input 3 Key Switch (ACC) ON/OFF
Step Light Sw. ON/OFF
02203 Switch Input 4
Horn Sw. ON/OFF
Over Load Sensor ON/OFF
05500 Sensor Input 1
Auto Greacing ON/OFF
03700 Controller Output 1 Batt. Relay Dr. ON/OFF
Step L.Pwr.Relay ON/OFF
Step L. Relay ON/OFF
03701 Controller Output 2
Flash L. Relay ON/OFF
Travel Alarm ON/OFF
20-172 PC750, 800-7

(1)

No. SI meter inch
Key Switch ON/OFF
Start ON/OFF
04500 Monitor Input 1 Preheat ON/OFF
Light ON/OFF
Rad. Level ON/OFF
Aircleaner ON/OFF
04501 Monitor Input 2 Eng. Oil Level ON/OFF
Battery Charge ON/OFF
Swing Brake Sw. ON/OFF
Bzzr Cancel Sw. ON/OFF
Window Limit Sw. ON/OFF
04502 Monitor Input 3 Display is a little different
W Limit Sw. ON/OFF between double-wiper speci-
Upper P Limit Sw./P Limit Sw. ON/OFF fication and single-wiper
specification.
Lower P Limit Sw./— ON/OFF
Key SW(C) ON/OFF
Eng. Oil Press. Lo ON/OFF
Eng. Controller Eng. Oil Press. Hi ON/OFF

17400
Input Machine Sel. 1 ON/OFF
Machine Sel. 2 ON/OFF
Machine Sel. 3 ON/OFF
36800 Q Adjust Switch R Numeral and alphabet
36801 Q Adjust Switch L Numeral and alphabet
Pump Controller ON/OFF
05100 S-NET Connection
Engine Controller ON/OFF
20200 Monitor Prog. Version Numeral
20212 Pump Con. Prog. Version Numeral
20209 Eng. Con. Prog. Version Numeral
a As the unit of display, one of "SI unit system", "Metric unit system", and "Inch unit system" can be selected.
a The unit of display can be changed with "Selection of unit" in the "AAAA/ Default" function of the service
menu.
a "CA" of the unit of display denotes the crankshaft angle.
Note 1: The momentary fuel consumption ratio shown above is the theoretical fuel consumption ratio (Since it is
a theoretical value, it is a little different from the actual fuel consumption ratio).
Note 2: The fuel consumption amount is the theoretical fuel consumption amount after the engine is started until
the engine is stopped (Since it is a theoretical value, it is a little different from the actual fuel consump-
tion amount).
PC750, 800-7 20-173

(1)
15. Function for Abnormality Record [02]

The monitor panel records failures that occurred
on the machines in the past after classifying
them into failures in the electric system and
those in the mechanical system. Information on
them can be displayed through the following
operation.
Select 02 Abnormality Record in the initial
display of Service Menu and depress [ ]
switch.
2) Selection of Submenu
Select an appropriate item from Submenu in
the Abnormality Record display and depress
[ ] switch.
No. Abnormality Record Submenu
Return
00
(termination of Abnormality Record)
01 Electrical Systems
02 Mechanical Systems
3) Information shown in display of Abnormality

Record in the electrical system
[1]: The numerator expresses sequence of
failure occurrence, counting from the
latest one. The denominator expresses
the total number of a specific failure
recorded.
[2]: Error Code
[3]: Abnormality Code No. (section in 4 dig-
its and phenomenon in 2 digits)
[4]: Time elapsed since the occurrence of
the first failure
[5]: Contents of failure
a Refer to "Table for Error Code and Ab-
normality Code" in Operator's Menu.
4) Information shown in display of Failure His-

tory in the mechanical systems
[1]: Record No.
[2]: Contents of Abnormality
[3]: Abnormality Code No. (section in 4 dig-
its and phenomenon in 2 digits)
[4]: Total number of occurrence
[5]: Service meter reading at the initial
occurrence
a Refer to "Table for Error Code and Ab-
normality Code" in Operator's Menu.
20-174 PC750, 800-7

(1)
5) Resetting Electrical Systems

a Resetting Electrical Systems (deletion)
is possible only with the electrical sys-
tem. The failure history in the mechani-
cal system cannot be reset.
a For resetting any specific or all informa-
tion in the Electrical Systems, follow the
operation explained below.
i) Through the following switch operation,
call the resetting display in the display of
Electrical Systems.
• Switch operation: [ ] +[1] o [2] o
[3]
a This is the same switch operation in
changing the display to Service
Menu.
ii) Operate the switch, following the instruc-
tions shown in the resetting display.
a When resetting specific information
only, call the display of that specific
information and reset it with either
[ ] switch or [ ] switch.
a When resetting all the information, a
display of any information will do.
PC750, 800-7 20-175

(1)
16. Function for Maintenance Record [03]

The monitor panel records information on the
maintenance of filters and oils. The stored infor-
mation can be displayed through the following
switch operation.
Select 03 Maintenance Record in Service
Menu and depress [ ] switch.
2) Information to be displayed
[1]: Name of oils and filters
[2]: Times of replacement to date
[3]: Service meter reading at the latest
replacement
20-176 PC750, 800-7

(1)
17. Function for Maintenance Mode Change [04]

Conditions set for controlling maintenance dis-
play function can be changed in the following
manner.
• Turn the function effectual or ineffectual.
• Change the set interval for replacement.
Select 04 Maintenance Mode Change in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of item to be changed

Select an item to be changed in the display
of Maintenance Mode Change Selecting
Menu.
No. Maintenance mode change item
Return (Termination of maintenance
00
mode change)
01 Maintenance Mode On/Off
02 Engine Oil Exch. Int.
03 Engine Oil Filter Exch. Int.
04 Fuel Filter Exch. Int.
05 Hydr. Oil Filter Exch. Int.
06 H/Tank Breather Exch. Int.
07 Corro. Resis. Exch. Int.
08 PTO Oil Service Int.
09 Final Drive Oil Exch. Int.
10 S/Machinery Oil Exch. Int.
11 Hydraulic Oil Exch. Int.
12 Pilot Filter Exch. Int.
13 Drain Filter Exch. Int.
14 Use Default Values
a 01 and 14 menus are provided for setting the

whole maintenance mode, while those from
02 through 13 are for setting individual items.
3) Contents of Maintenance Mode On/Off

• Use: The maintenance display function
of all oil and filter-related items are
turned effectual. (Irrespective of whether
"On" or "Off" set for individual items, this
setting prevails)
• Do not use: The maintenance display
function of all oil and filter-related items
are turned ineffectual. (Irrespective of
whether "On" or "Off" set for individual
items, this setting prevails)
PC750, 800-7 20-177

(1)
4) Set contents of individual items

[1]: Default: The maintenance time set in
the monitor (recommended by the man-
ufacturer and cannot be changed).
[2]: Set: Maintenance time that can be
freely set. The maintenance mode pro-
gram functions based on this mainte-
nance time. (The maintenance time can
be increased or decreased by 50 hours
with [ ] or [ ] switch)
[3]: On: Maintenance display function with
this instruction becomes effectual.
[4]: Off: Maintenance display with this
instruction becomes ineffectual.
a The lowest maintenance time is 50 h.
5) Set contents of "Use Default Values"

When selecting this menu and depressing
the switch [ ], all individual time settings
are reduced to the initial settings.
20-178 PC750, 800-7

(1)
18. Function for Phone Number Entry [05]

In the display of User Code, a telephone number
and Service Code are shown alternately. Phone
number can be inputted or modified in the fol-
lowing manner.
a If there is no Phone number registered, the
display for Phone numbers does not appear.
Select 05 Phone Number Entry menu in the
display of Service Menu, and depress [ ]
switch.
2) Changing the display

Select Entry next to change the display to
the Phone Number Entry display.
a Even if a Phone number is already input-
ted, it is deleted, upon switching to the
Phone Number Entry display.
3) Entry and setting Phone number

Following the method explained below,
Entry a Phone number in the Phone Num-
ber Entry display. (Entry automatically
begins with a cursor at the left end)
i) Enter a number into a cursor at the left
end with a ten-key.
ii) Depress [ ] switch when all the num-
bers have been entered.
a Numbers can be entered up to the max.
12 digits, but omit unnecessary digits.
a When entering a wrong number, de-
press [Swing priority] switch, then the
cursor goes back by one digit.
a When input is finished, the display
changes to Entry display shown above.
If the inputted Phone number is shown in
this display, the input is normal.
PC750, 800-7 20-179

(1)
19. Function for AAAA/Default

AAAA [06]
It is possible to change the following settings for
the monitor panel as well as the machine. Make
a change as is required.
• Working mode when the engine starting
switch is in the ON position.
• Display language in Service Menu
• Display unit in the monitoring function
• Setting of double wiper or single wiper
Select 06 "AAAA/Default menu" in the ini-
tial display of Service Menu, and depress
[ ] switch.
2) Selection of submenu
Select an item to change from the submenu,
and depress [ ] switch.
No. AAAA/Default submenu
00 Return (termination of AAAA/Default)
01 Key-on Mode
02 AA/Language
03 Unit
04 Wiper Select
3) Function for Key-on Mode

When the engine starting switch is turned
ON, a working mode can be set that is
shown in the monitor panel.
• A Mode, E Mode, Heavy Lift Mode OFF/
ON, Swing Priority Mode OFF/ON: If any
of them is set, the machine always
ramps up with that working mode, when
turning the engine starting switch ON.
• Mode at Previous Key-off: If this mode is
set, the machine ramps up with the
working mode that was last used in the
previous machine operation.
• Default Value: If this mode is set, the
machine ramps up with the default mode
(A mode) that was originally set at the
time of delivery from the factory.
20-180 PC750, 800-7

(1)
4) Function for AA/Language

In Service Menu, the language in use can
be changed between Japanese and
English.
a English is used as the language for de-
fault setting in the monitor panel.
a If the monitor panel for spare parts is to
be used in a Japanese-speaking region
or organization, change the language
from English to Japanese, using this
function.
5) Function for unit selection

As the unit to be used in the monitoring
function display of Service Menu, three
kinds of unit are provided.
a Unit used for default setting in the moni-
tor panel is SI, i.e. International System
of Units.
6) Function for selection of wiper specification

The wiper specification can be set.
• 1 wiper: Machine with standard cab or
fixed-front window cab
(Only upper wiper)
• 2 wipers: Machine with fixed-front win-
dow cab (if equipped)
(Upper wiper and lower wiper)
a If this setting is not matched to the spec-
ification of the actually installed wiper,
the wiper may not operate normally or an
error is detected.
PC750, 800-7 20-181

(1)
20. Function of adjustment [07]

The machine can be adjusted with the monitor
panel.
Select "07 Adjustment" on the service menu
and press the [ ] switch.
2) Selection of sub menu

Select the sub menu to check the setting
and press the [ ] switch.
No. Sub menu of adjustment
00 Return (Finish adjustment)
01 Pump Absorption Torque
3) Function of pump absorption torque

The pump absorption torque can be
adjusted in the following ranges.
a Basically, this setting does not need to
be changed.
Adjustment
Sub menu of adjustment
value
220 +98.1 Nm {+10.0 kgm}
221 +73.5 Nm {+7.5 kgm}
222 +49.0 Nm {+5.0 kgm}
223 +24.5 Nm {+2.5 kgm}
224 0.0 Nm {0.0 kgm}
225 –24.5 Nm {–2.5 kgm}
226 –49.0 Nm {–5.0 kgm}
227 –73.5 Nm {–7.5 kgm}
228 –98.1 Nm {–10.0 kgm}
20-182 PC750, 800-7

(1)
21. Function of reduced cylinder mode operation

[08]
The reduced cylinder mode can be controlled
with the monitor panel.
Reduced cylinder mode operation means to run
the engine with 1 or more fuel injectors disabled
electrically to reduce the number of effective cyl-
inders. This operation is used to find out a cylin-
der which does not output power normally (or,
combustion in it is abnormal).
Select "08 Cylinder cut out" on the initial
screen of the service menu and press the
[ ] switch.
2) Setting of cylinders to be disabled

Press switches [1] – [6] on the monitor panel
corresponding to the cylinder Nos. to be dis-
abled.
a After a switch is pressed, if the cylinder
No. corresponding to it on the monitor
panel is displayed white in a white frame,
the cylinder is disabled (If setting is
wrong, press the same switch again).
a Only one or more cylinders can be disa-
bled for the reduced cylinder mode oper-
ation.
3) Cancellation of disabled cylinders

Press switches [1] – [6] on the monitor panel
corresponding to the disabled cylinder Nos.
to cancel disabling of those cylinders.
a After a switch is pressed, if the cylinder
No. corresponding to it on the monitor
panel is displayed black in a black frame,
disabling of the cylinder is cancelled.
PC750, 800-7 20-183

(2)
4) Function of holding engine speed

If the [ ] switch is pressed while the
reduced cylinder mode operation screen is
used, the engine speed is held and dis-
played on the lower line.
If the [ ] switch is pressed while the engine
speed is held, holding of the engine speed is
cancelled and the engine speed displayed
on the lower line goes off.
a If the holding function is used, the held
engine speed is displayed in ( ) on the
lower line and the current engine speed
is displayed on the upper line.
a The holding function can be used both in
and out of the reduced cylinder mode.
[Reference]: How to use holding function effec-

tively
The engine speed displayed by the holding
function is held on the screen until the holding
function is cancelled, regardless of setting and
cancellation of the reduced cylinder mode.
Accordingly, a defective cylinder can be found
out effectively according to the following proce-
dure.
(1) Run the engine normally (without disabling
any cylinder) and hold the engine speed.
(2) Disable a cylinder to be checked.
(3) Run the engine under the same condition as
the normal operation in step (1) and com-
pare the engine speed at this time with the
held engine speed.
(4) If there is not a difference between the cur-
rent engine speed and the held engine
speed in step (3), cancel the reduced cylin-
der mode.
(5) Repeat steps (2) - (4) to check the other cyl-
inders.
20-184 PC750, 800-7

(1)
TESTING AND ADJUSTING HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT
k The engine controller is equipped with high volt-

age circuits (110-130 V) for driving the fuel in-
jector.
They are connected to the connectors and har-
nesses between the engine controller and the
fuel injector.
a Normally, a high voltage is only output while the
engine is running. Once the engine is stopped,
k Touching the high voltage circuit directly may

the output ceases.
cause an electric shock. To avoid this, observe

the following precautions when inspecting the
circuits.
1. Connectors containing high voltage circuits:

• Engine controller connector: E13
• Relay connector: A13, A14
• Injector connector: CN1, CN2, CN3, CN4,
CN5, CN6
• Injector head terminal (in head cover)
2. Be sure to connect and disconnect the relevant

connectors with the starting switch off.
3. When diagnosing, do not start the engine with

the T-adapter inserted in or connected to the rel-
evant connector.
a At that time, the starting switch can be set to
ON and OFF only, but not to START.
PC750, 800-7 20-185

(1)
TESTING AND ADJUSTING PREPARATION WORK
PREPARATION WORK
a When troubleshooting an electric circuit related 2. Engine controller
to the monitor panel, engine controller, or pump 1) Slide the operator's seat and seat stand for-
controller, expose the related connectors ward to the stroke end.
according to the following procedure. 2) Insert or connect T-adapters for trouble-
shooting to connectors E11, E12, and E13
1. Monitor panel of engine controller (3).
1) Remove cover (1). a Since the connectors are secured with
a The cover is secured with 2 clips at the screws, loosen those screws before dis-
top and bottom. Those clips can be re- connecting them.
moved by pulling them up. a After returning the connectors, tighten
3 Screw: 2.82 Nm {0.288 kgm}

a If a sunlight sensor for the air conditioner the screws to the specified torque.
is installed, disconnect connector P15
on the backside of the cover.
3. Pump controller
2) Remove the 3 mounting screws and discon- a The pump controller is installed in the cover
nect monitor panel (2) from the mount. at the rear of the operator's seat.
a Take care not to drop the mounting 1) Remove 3 caps (4) and 3 mounting bolts.
screws in the console. a Remove the caps with a thin flat-head
3) Insert or connect T-adapters for trouble- screwdriver.
shooting to connectors P01, P02, and P70 2) Remove cover (5).
of the monitor panel.
20-186 PC750, 800-7

(1)
TESTING AND ADJUSTING PREPARATION WORK
3) Insert or connect T-adapters for trouble-

shooting to connectors C01, C02, and C03
of the pump controller (6).
a Since the connectors are secured with
screws, loosen those screws before dis-
connecting them.
a After returning the connectors, tighten
3 Screw: 2.82 Nm {0.288 kgm}

the screws to the specified torque.
PC750, 800-7 20-187

(1)
PM-CLINIC SERVICE
Specification of machine
PC750, 800-7 20-189

(1)
MEASURING PROCEDURES
Positions to install measuring devices (Related to engine and PTO)
20-190 PC750, 800-7

(1)
MEASURING PROCEDURES
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)
PC750, 800-7 20-191

(1)
20-192 PC750, 800-7
(1)
PC750, 800-7 20-193
(1)
Pm-CLINIC SERVICE PC750 (LC, SE), 800 (SE)-7
Visual check of welded structures (For PC750, 750LC, 800-7)
a If any crack is found, draw its shape below.
Arm Boom Revolving frame

1. Arm cylinder bracket 4. Boom top bracket 9. Boom bracket
T Left T Right T Left T Right T Left T Right
2. Arm foot 5. Boom cylinder bracket
T Left T Right T End plate T Left T Right Track frame
3. Arm top boss 6. Arm cylinder bracket 10. Circle bracket
T Left T Right T Left T Right T Front T Rear
7. Boom lower plate T Left T Right
T Left T Right 11. Track frame mounting section
8. Boom foot T Front T Rear
T Left T Right T Left T Right
20-194 PC750, 800-7

(1)
Visual check of welded structures (For PC750SE, 800SE-7)
a If any crack is found, draw its shape below.
Arm Boom Revolving frame

1. Arm cylinder bracket 4. Boom top bracket 9. Boom bracket
T Left T Right T Left T Right T Left T Right
2. Arm foot 5. Boom cylinder bracket
T Left T Right T End plate T Left T Right Track frame
3. Arm top boss 6. Arm cylinder bracket 10. Circle bracket
T Left T Right T Left T Right T Front T Rear
7. Boom lower plate T Left T Right
T Left T Right 11. Track frame mounting section
8. Boom foot T Front T Rear
T Left T Right T Left T Right
PC750, 800-7 20-195

(1)
TESTING AND ADJUSTING UNDERCARRIAGE INSPECTION
UNDERCARRIAGE INSPECTION
(Program form No.: ***************)
20-196 PC750, 800-7

(1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202
SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...................... 20-217
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-234
T-BRANCH BOX AND T-BRANCH TABLE................................................................................................. 20-256
TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND
FAILURE CODE "MECHANICAL SYSTEM" ARE DISPLAYED........................................................... 20-301
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) ................................................................. 20-501
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) ................................. 20-601
TROUBLESHOOTING OF ENGINE (S MODE).......................................................................................... 20-701
PC750, 800-7 20-201

(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
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 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or a 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
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
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 ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the a The basic procedure for troubleshooting
machine 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
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
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.
4) Check the stroke of the control valve spool.
20-202 PC750, 800-7

(1)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC750, 800-7 20-203

(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, 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, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-204 PC750, 800-7

(1)
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.
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-circuited by the water, so if any
water gets in, immediately dry the connector
or take other appropriate action before
passing electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating 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-
tact restorer.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.
PC750, 800-7 20-205

(1)
2) Removing, installing, and drying connectors

and wiring harnesses
• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull with one hand.
2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
a If the connector is twisted up and down
or to the left or right, the housing may
break.
3) Action to take after removing connectors

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
a If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 PC750, 800-7

(1)
• 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,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the 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.
a 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.
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 wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
4) If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
PC750, 800-7 20-207

(1)
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move 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.
a Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
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.
a After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 PC750, 800-7

(1)
3) Handling control box

1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.
3) Do not place objects on top of the control

box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in that circuit.
PC750, 800-7 20-209

(1)
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling 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
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt or dust get in during refill-

ing 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.
20-210 PC750, 800-7

(1)
5) Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants 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
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.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
PC750, 800-7 20-211

(1)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil,
4. Check hydraulic oil strainer — Clean, drain

coolant
5. Check swing machinery oil level — Add oil

6. Check engine oil level (oil pan oil level) — 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, burnt, exposed wiring — Replace

4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention to — Disconnect
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 Replace
running for
several
minutes :
27.5 – 29.5V
8. Check operating sound of battery relay — Replace
(when switch is turned ON/OFF)
20-212 PC750, 800-7

(1)
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Classification of troubleshooting
Mode Content
Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are
Code display
displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine
Steps for troubleshooting

If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting
No. and proceed to the explanations for diagnosis.
1. Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [ ] switch to display Error Code. Following displayed Error
Code for the electrical system, carry out the troubleshooting along the corresponding code display.
2. Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is
recorded in the failure history:
If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system
Failure Code, using the failure history function of the monitor panel.
a If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the
display again to check if the same abnormality still persists.
a Failure Code in the mechanical system cannot be deleted.
3. Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that
the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechan-
ical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from
among "Failure like Phenomena and Troubleshooting No." and carry out E mode or H mode troubleshooting
related to the phenomenon in question.
PC750, 800-7 20-213

(1)
Failure-looking Phenomenon and Troubleshooting No.
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Action to be taken concerning Error Code, User Code and Failure Code
1 Display User Code in monitor panel
Accord-
2 Display Error Code in electrical system after checking failure historying to
displayed
Display Failure Code in mechanical system after checking failure his-
3 code
tory
Engine-related failure
4 Starting performance is poor (starting always takes time) S-1
5 Engine does not turn E-1 S-2 a)
Engine turns but no exhaust smoke
6 S-2 b)
Engine does not start comes out
Exhaust smoke comes out but engine
7 S-2 c)
does not start (Fuel is being injected)
8 Engine does not pick up smoothly (follow-up is poor) S-3
9 Engine stops during operations S-4
10 Engine does not rotate smoothly (hunting) S-5
11 Engine lacks output (or lacks power) S-6
12 Exhaust smoke is black (incomplete combustion) S-7
13 Oil consumption is excessive (or exhaust smoke is blue) S-8
14 Oil becomes contaminated quickly S-9
15 Fuel consumption is excessive S-10
16 Oil is in cooling water (or water spurts back, or water level goes down) S-11
17 Oil pressure caution lamp lights up (drop in oil pressure) S-12
18 Oil level rises (water, fuel in oil) S-13
19 Water temperature becomes too high (overheating) S-14
20 Abnormal noise is made S-15
21 Vibration is excessive S-16
22 Preheater does not operate E-2
23 Auto engine warm-up device does not work E-3
24 Auto-decelerator does not operate E-4
Failure related to work equipment, swing and travel
25 Speed or power of all work equipment, travel, and swing is low H-1
26 Engine speed lowers remarkably or engine stalls H-2
27 All work equipment, travel, and swing systems do not work E-5 H-3
28 Abnormal sound is heard from around pump H-4
Work equipment-related failure
29 Boom speed or power is low H-5
30 Speed or power of arm is low H-6
31 Speed or power of bucket is low H-7
20-214 PC750, 800-7

(1)
Troubleshooting
display
32 Boom does not move H-8
33 Arm does not move H-9
34 Bucket does not move H-10
35 Hydraulic drift of work equipment is large H-11
36 Time lag of work equipment is large H-12
37 Heavy lift function does not operate or stop H-13
38 Machine push-up function does not operate or stop E-6 H-14
39 Boom shockless function cannot be turned ON or OFF E-7 H-15
Travel-related failure
40 Machine deviates in one direction H-16
41 Machine deviates largely at start H-17
42 Machine deviates largely during compound operation H-18
43 Travel speed or power is low H-19
44 Machine does not travel (only one track) H-20
45 Travel speed does not change H-21
46 Travel alarm does not sound or does not stop sounding E-32
Swing-related falure
47 Upper structure does not swing H-22
48 Swing speed or acceleration is low H-23
Swing speed or acceleration is low during compound operation of
49 H-24
swing and work equipment
50 Upper structure overruns excessively when it stops swinging H-25
51 Large shock is made when upper structure stops swinging H-26
52 Large abnormal sound is made when upper structure stops swinging H-27
53 Hydraulic drift of swing is large H-28
Monitor panel-related failure (Operator’s Menu: ordinary Display)
54 Any item is not displayed on monitor panel E-8
55 Part of display on monitor panel is missing E-9
56 Monitor panel displays contents irrelevant to the model E-10
57 Fuel level monitor red lamp lights up while engine is running E-11
58 Engine water thermometer does not display normally E-12
59 Hydraulic oil temperature gauge does not display correctly E-13
60 Fuel gauge does not display correctly E-14
61 Swing lock monitor does not display correctly E-15
62 When monitor switch is operated, nothing is displayed E-16
63 Windshield wiper and window washer do not work E-17
64 Alarming buzzer cannot be cancelled E-18
PC750, 800-7 20-215

(1)
Troubleshooting
display
Monitor panel-related failure (Service Menu: Special Function Display)
65 "Boom RAISE" is not correctly displayed in monitor function E-19
66 "Boom LOWER" is not correctly displayed in monitor function E-20
67 "Arm IN" is not correctly displayed in monitor function E-21
68 "Arm OUT" is not correctly displayed in monitor function E-22
69 "Bucket CURL" is not correctly displayed in monitor function E-23
70 "Bucket DUMP" is not correctly displayed in monitor function E-24
71 "SWING" is not correctly displayed in monitor function E-25
72 "Left travel" is not displayed normally in monitoring function E-26
73 "Right travel" is not displayed normally in monitoring function E-27
74 "Service" is not correctly displayed in monitor function E-28
Other failure
75 Air conditioner does not work E-29
76 Step light does not light up or go off E-30
77 Electric grease gun does not operate E-31
20-216 PC750, 800-7

(1)
CONNECTOR LOCATION CHART AND ELECTRI-
TROUBLESHOOTING CAL CIRCUIT DIAGRAM BY SYSTEM
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT

DIAGRAM BY SYSTEM
Connector table
Address
Connector Connector No. of
Place of use Stereo- M E P
No. Type pin
gram circuit circuit circuit
A01 X 4 Intermediate connector S-1 H-7 G-7
A02 X 4 Intermediate connector T-1 H-6 G-7
A03 DT 6 Intermediate connector N-2 G-7
A05 DT 12 Intermediate connector (Gray) T-1 H-6 G-6
A06 DT 12 Intermediate connector (Green) N-1 H-5 G-6
A07 SWP 16 Intermediate connector (Black) S-1 H-5 G-5
A09 SWP 8 Intermediate connector (Gray) N-2 G-5
A10 DT 6 Intermediate connector O-1 H-4 E-7 G-5
A11 DT 12 Intermediate connector (Black) S-1 E-7
A12 DT 12 Intermediate connector (Green) T-1 E-6
A13 DT 12 Intermediate connector (Gray) S-9 E-5
A14 DT 12 Intermediate connector (Black) T-9 E-4
B Terminal 2 Battery relay terminal B B-9 J-7 I-1 L-7
B01 HD30 21 Circuit breaker box A-2 K-8 I-1 K-7
B02 DT 1 Circuit breaker box D-9 K-8 K-7
B03 DT 1 Circuit breaker box A-1 K-8 K-7
B11 Terminal 1 Circuit breaker 1 A-2 L-8
B12 Terminal 1 Circuit breaker 2 L-8 L-7
B13 Terminal 1 Circuit breaker 3
B14 Terminal 1 Circuit breaker 4 L-7
B16 Terminal 1 Circuit breaker 6 L-7 J-1
B17 Terminal 1 Circuit breaker 7 J-1
B21 Terminal 1 Circuit breaker 1 L-8 L-7
B23 Terminal 1 Circuit breaker 3
B26 Terminal 1 Circuit breaker 6 L-7 J-1
B27 Terminal 1 Circuit breaker 7 J-1
B29 Terminal 1 Circuit breaker 9 A-2 L-7
BR Terminal 1 Battery relay terminal BR A-6 J-7 H-1 L-7
C01 DRC 24 Pump controller V-9 A-3 A-8 A-8
C02 DRC 40 Pump controller W-9 A-3 A-8 A-7
C03 DRC 40 Pump controller W-9 A-2 A-6
C09 S 8 Model selection connector (for pump controller) W-6 B-1
C13 DT 2 TVC solenoid L-6 L-4
CN1 DT 2 No. 1 fuel injector AF-7 K-4
CN2 DT 2 No. 2 fuel injector AG-8 K-3
CN3 DT 2 No. 3 fuel injector AH-8 K-4
CN4 DT 2 No. 4 fuel injector AI-8 K-3
PC750, 800-7 20-217

(1)
a The addresses roughly show the places of the connectors in the 3-dimensional connectors arrangement
drawing and the electric circuit diagram of each system.
Address
No. Type pin
D01 SWP 8 Assembled-type diode W-7 E-9 A-4
D02 SWP 8 Assembled-type diode W-7 F-9 A-3
D03 SWP 8 Assembled-type diode R-1 A-3
D04 SWP 8 Assembled-type diode Q-1 A-3
D05 SWP 8 Assembled-type diode Q-1 F-9 A-2
D06 SWP 8 Assembled-type diode Q-1 F-9
D07 KES1 2 Diode S-9 E-9
D08 KES1 2 Diode S-9 E-9
E Terminal 1 Battery relay terminal E A-7 J-7 H-2 L-7
E06 M 3 Fuel control dial O-8 K-8
E09 S 8 Model selection connector (for engine controller) W-5 A-1
E11 DRC 24 Engine controller V-1 K-2 A-7 F-4
E12 DRC 40 Engine controller V-1 K-1 A-6 F-3
E13 DRC 40 Engine controller V-1 A-4
E21 HD30 31 Intermediate connector AJ-4 I-4
E22 HD30 31 Intermediate connector AJ-3 J-4 I-7 K-6
ENE DT 2 Engine speed sensor AJ-6 L-6
F01 X 2 Travel alarm L-8 L-5
F02 YAZAKI 2 Intermediate connector AA-9
FB1 — — Fuse box W-3 H-7 G-8
G YAZAKI 2 Engine G sensor AH-2 K-5
G11 X 2 Electric grease gun A-5
G12 X 2 Electric grease gun remote switch A-3
H08 M 8 Intermediate connector W-4 D-7
H09 S 8 Intermediate connector W-4 D-7 D-1
B-1
H10 S 16 Intermediate connector T-9 J-8 E-2
D-6
B-1
H11 S 16 Intermediate connector T-9 E-2
D-5
H12 S 12 Intermediate connector U-9 D-4 J-7 E-2
H15 S090 20 Intermediate connector N-7 D-3 I-9 A-2
HT Terminal 3 Heater relay AJ-5 K-2
J01 J 20 Joint connector (Black) W-8 C-9 G-9 A-9
J02 J 20 Joint connector (Black) W-8 C-9 G-9 A-9
J03 J 20 Joint connector (Pink) W-8 D-9 B-9
J04 J 20 Joint connector (Green) W-7 D-9 B-9
J05 J 20 Joint connector (Pink) W-6 E-9 C-9
J06 J 20 Joint connector (Orange) W-6 C-9
J07 J 20 Joint connector (Green) V-9 E-9 D-9
J08 J 20 Joint connector (Pink) U-9 G-9 D-9
J09 J 20 Joint connector (Black) X-2 D-9
J11 DT 8 Joint connector L-8 H-9
J12 DT 8 Joint connector L-6 H-9
J13 DT 8 Joint connector K-2 I-9
J14 DT 8 Joint connector L-5 I-9 H-9 I-9
J15 DT 8 Joint connector J-9 I-9
J16 DT 8 Joint connector J-9 H-9
J17 DT 8 Joint connector K-9 I-9
J18 DT 6 Joint connector F-9 I-9 I-9
20-218 PC750, 800-7

(1)
Address
No. Type pin
J19 DT 6 Joint connector H-1 J-9
J20 DT 6 Joint connector L-7 I-9 J-9
J21 DT 6 Joint connector I-9 J-9 J-9
J22 DT 8 Joint connector D-1 J-9 J-9
K19 M 2 Pump resistor (for driving pump in emergency) U-2 B-1
K30 DT 3 CAN terminal resistor W-2 K-1 A-1 F-3
K31 DT 3 CAN terminal resistor N-4 A-4 K-7 E-1
M Terminal 1 Battery relay terminal M C-9 J-7 I-2 L-7
M07 M 3 Light switch P-8 D-1
M08 M 1 Working lamp (Boom) B-9 H-1
M09 M 1 Working lamp (Boom) A-9 H-1
M10 X 1 Intermediate connector E-9 H-2
M13 KES0 2 Speaker (Right) AC-8
M16 Terminal 1 Horn (High tone) C-1 G-9
M17 Terminal 1 Horn (Low tone) B-1 H-9
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio U-2
M22 Y090 2 Horn switch N-7 B-1
M26 S 12 Air conditioner unit W-5
M28 SWP 2 Windshield washer motor I-1 K-8
M31 M 2 Optional power supply (2) U-2
M32 M 2 Optional power supply (1) S-9
M33 M 2 Optional power supply (3) W-3
M34 X 1 Air conditioner compressor electromagnetic clutch AG-2
M37 Terminal 1 Horn (High tone) D-1 G-9
M38 Terminal 1 Horn (Low tone) C-1
M38 M 2 Machine push-up switch R-9 A-1
M39 M 3 Boom shockless control switch W-4 F-1
M40 YAZAKI 2 Headlamp Z-8 A-8
M41 YAZAKI 2 Headlamp Y-7 A-8
M42 M 1 Right headlamp A-3 I-1
M45 DT 12 Intermediate connector U-2
M46 X 4 RS232C junction connector N-3 A-4
M71 M 2 Room lamp Z-8
M72 M 4 DC/DC converter U-2
M73 KES0 2 Speaker (Left) AD-8
M75 YAZAKI 2 Step light AB-1 D-1
M79 YAZAKI 2 12-V accessory socket V-9
M80 X 1 Intermediate connector E-1 G-9
M81 M 2 Step light switch AD-2 F-1
M82 M 1 Flash light E-1 G-9
M95 X 4 Intermediate connector D-1 G-9
NE YAZAKI 2 Engine Ne sensor AJ-4 K-5
OL DT 2 Engine oil level sensor AH-2 K-3
A-7
P01 070 12 Monitor panel N-6 K-8 E-1
A-1
A-6
P02 040 20 Monitor panel N-5 K-8 E-1
A-1
P03 M 2 Alarm buzzer stop switch P-9 D-1
P05 M 2 Rotary lamp switch W-4
P06 DT 2 Fuel level sensor C-9 K-4
PC750, 800-7 20-219

(1)
Address
No. Type pin
P08 X 2 Radiator water level switch L-7 K-5
P10 DT 2 Hydraulic oil temperature sensor L-5 K-6
P11 DT 2 Air cleaner clogging switch I-9 K-5
P15 Y050 2 Air conditioner sunlight sensor N-6
P16 YAZAKI 2 Air conditioner outside temperature sensor H-9
P20 X 2 Radiator water level switch L-8 K-5
P30 DT 3 Front pump pressure sensor H-9 L-5
P31 DT 3 Rear pump pressure sensor J-9 L-5
P70 040 16 Monitor panel N-4 A-5 K-7 E-1
PCV1 SUMI 2 Fuel supply pump PCV1 AG-2 K-3
PCV2 SUMI 2 Fuel supply pump PCV2 AH-2 K-2
PFUEL AMP 3 Common rail pressure sensor AH-3 K-7
PIM SUMI 3 Boost pressure sensor AG-7 K-6
PSH Terminal 1 Engine oil pressure switch (High pressure) AI-3 L-5
PSL Terminal 1 Engine oil pressure switch (Low pressure) AI-3 L-6
R10 R 5 Light relay O-8 G-1
R11 R 5 Starting motor cut-out relay (PPC lock) P-8 G-1
R13 R 5 Starting motor cut-out relay (Personal cord) Q-9 H-1
R14 R 5 Step light power supply drive relay W-5 F-9
R15 R 5 Step light relay W-5 E-9
R20 R 5 Horn relay W-6 E-9
R21 R 5 Flash light relay W-7 E-9
R22 R 5 Engine controller power supply relay W-5 B-9
S01 X 2 Right travel forward PPC oil pressure switch G-1 K-3
S02 X 2 Boom RAISE PPC oil pressure switch K-2 K-2
S03 X 2 Arm OUT PPC oil pressure switch L-3 K-2
S04 X 2 Boom LOWER PPC oil pressure switch K-2 K-2
S05 X 2 Arm IN PPC oil pressure switch L-3 K-2
S06 X 2 Bucket CURL PPC oil pressure switch L-2 K-2
S07 X 2 Bucket DUMP PPC oil pressure switch L-2 K-2
S08 X 2 Swing RIGHT PPC oil pressure switch L-4 K-2
Service PPC oil pressure switch
S09 X 2 J-1 K-1
(Intermediate connector)
S10 X 2 Swing LEFT PPC oil pressure switch L-3 K-1
S11 X 2 Right travel reverse PPC oil pressure switch H-1 K-1
S12 X 2 Left travel forward PPC oil pressure switch H-1 K-1
S13 X 2 Left travel reverse PPC oil pressure switch I-1 K-1
S14 M 3 Safety lock lever switch S-1 F-2 F-9
S21 Terminal 6 Emergency pump drive switch R-9 C-1
S22 Terminal 6 Swing holding brake release switch R-9 D-1
S25 S090 16 Intermediate connector Q-9
ST DT 2 Starting motor AH-8 K-4 K-6
T02 Terminal 1 Revolving frame ground A-6 K-6 K-8
T03 Terminal 1 Revolving frame ground A-6 K-6 K-8
T04 Terminal 1 Revolving frame ground A-4 G-1
T05 Terminal 1 Floor frame ground W-3 F-7 D-2
T06 Terminal 1 Radio body ground T-2
T06A M 1 Intermediate connector T-1
T08 Terminal 1 Engine controller ground V-1 A-1
T09 Terminal 2 Revolving frame ground A-4 L-6 K-8
T10 Terminal 1 Revolving frame ground F-1 H-8
20-220 PC750, 800-7

(1)
Address
No. Type pin
T11 Terminal 1 Cab ground AD-3
T12 Terminal 1 Revolving frame ground A-4 L-6 K-8
T14 Terminal 2 Revolving frame ground A-4 G-1
THL DT 3 Spill fuel temperature sensor AI-3 K-4
TWH DT 2 Engine water temperature sensor (High temperature) AE-7 K-6
TWL DT 3 Engine water temperature sensor (Low temperature) AF-7 K-6
V01 DT 2 Swing priority solenoid valve G-1 G-2
V02 DT 2 2-stage relief solenoid valve L-8 G-2
V03 DT 2 Travel junction solenoid valve L-5 G-2
V04 DT 2 Swing holding brake solenoid valve F-9 G-2
V05 DT 2 Machine push-up solenoid valve G-9 G-2
V06 DT 2 Travel speed selector solenoid valve G-9 G-2
V07 DT 2 CO cancel solenoid valve L-4 G-1
V08 DT 2 PPC oil pressure lock solenoid valve G-1 G-1
V09 DT 2 Boom shockless control solenoid valve (Raise) J-1 G-1
V10 DT 2 Boom shockless control solenoid valve (Lower) J-1 G-1
W03 X 2 Window rear limit switch [Single-wiper specification] AB-9 A-9
B-2
W04 M 6 Wiper motor Y-4
B-7
W05 M 6 Lower wiper motor [Double-wiper specification] E-1 G-9
W06 M 2 Lower wiper switch [Double-wiper specification] W-4 E-1
X05 M 4 Swing lock switch Q-9 E-1 A-1
Connector type Detailed information

DT Japanese and German makes DT type connector (08192-XXXXX)
J Product of Sumitomo Wiring Systems 090 type splice
M Product of Yazaki M type connector (08056-0XXXX)
R Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S Product of Yazaki S type connector (08056-1XXXX)
X Product of Yazaki X type connector (08055-0XXXX)
PA Product of Yazaki PA type connector
SWP Product of Yazaki SWP type connector (08055-1XXXX)
DRC Japanese and German makes DRC type connector
040 Product of Japan 040 type connector
070 Product of Japan 070 type connector
Y050 Product of Yazaki 050 type connector
S090 Product of Sumitomo 090 type connector
Y090 Product of Yazaki 090 type connector
YAZAKI Yazaki-made connector
KES0 KES0 type connector (08027-0XXXX)
Terminal Round pin type or single terminal connector
KES1 KES1 type connector (08027-1XXXX)
HD30 Japanese and German makes HD30 type connector (08191-XXXXX)
AMP Product of Japan AMP type connector
SUMI Product of Sumitomo-made connector
PC750, 800-7 20-221

(1)
Connector Location Stereogram
20-222 PC750, 800-7

(1)
PC750, 800-7 20-223

(1)
20-224 PC750, 800-7

(1)
PC750, 800-7 20-225

(1)
20-226 PC750, 800-7

(1)
PC750, 800-7 20-227

(1)
Monitor Panel System Circuit Diagram (M Circuit)
20-228 PC750, 800-7

(1)
a This circuit diagram is made by extracting the monitor panel system, engine preheating/starting/charging
system, light system, and communication network system from the general electric circuit diagram.
PC750, 800-7 20-229

(1)
Engine Control System Circuit Diagram (E Ciruit)
20-230 PC750, 800-7

(1)
a This circuit diagram is made by extracting the engine controller system from the general electric circuit dia-
gram.
PC750, 800-7 20-231

(1)
Pump Controller System Circuit Diagram (P Circuit)
20-232 PC750, 800-7

(1)
a This circuit diagram is made by extracting the pump controller system, PPC lock solenoid system, machine
push-up solenoid system, and boom shockless solenoid system from the general electric circuit diagram.
PC750, 800-7 20-233

(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
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
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-234 PC750, 800-7

(1)
SWP type connector

No.of
pins T-adapter
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, 800-7 20-235

(1)
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-236 PC750, 800-7

(1)
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
PC750, 800-7 20-237

(1)
S type connector
No.of
pins T-adapter
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
20-238 PC750, 800-7

(1)
S type connector
No.of
pins T-adapter
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, 800-7 20-239

(1)
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
20-240 PC750, 800-7

(1)
MIC type connector

No.of
pins T-adapter Part
No.
17 799-601-2730
21 799-601-2740
—
(Q’ty: 50) (Q’ty: 50)
PC750, 800-7 20-241

(1)
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
a Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-242 PC750, 800-7

(1)
AMP070 type connector

No.of
pins T-adapter 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, 800-7 20-243

(1)
L type connector
No.of
pins T-adapter Part
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460
— —
20-244 PC750, 800-7

(1)
KES 1 (Automobile) connector

No.of
pins T-adapter 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, 800-7 20-245

(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
8 —
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No.of
pins T-adapter Part
No.
5 799-601-7360
— —
6 799-601-7370
— —
20-246 PC750, 800-7

(1)
F type connector
No.of
pins T-adapter
Part No.
4 —
— —
PC750, 800-7 20-247

(1)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) 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
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-248 PC750, 800-7

(1)

(shell
size T-adapter
code) 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
PC750, 800-7 20-249

(1)

(shell
size T-adapter
code) 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
20-250 PC750, 800-7

(1)

(shell
size T-adapter
code) 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 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
PC750, 800-7 20-251

(1)

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
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
20-252 PC750, 800-7

(1)
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
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
PC750, 800-7 20-253

(1)
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter 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
12
12G: 799-601-9130
12BR: 799-601-9140
20-254 PC750, 800-7

(1)
DTM Series connector

No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter 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)
PC750, 800-7 20-255

(1)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P
799-601-3200 Measurement box MS-37P
799-601-3300 Measurement box Econo-24P
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P
799-601-3420 BENDIX (MS) 24P
799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P
799-601-3450 BENDIX (MS) 5P
799-601-3460 BENDIX (MS) 10P
799-601-3510 BENDIX (MS) 5P
799-601-3520 BENDIX (MS) 14P
799-601-3530 BENDIX (MS) 19P
799-601-2910 BENDIX (MS) 14P
799-601-3470 Case
799-601-2710 MIC 5P
799-601-2720 MIC 13P
799-601-2730 MIC 17P
799-601-2740 MIC 21P
799-601-2950 MIC 9P
799-601-2750 ECONO 2P
799-601-2760 ECONO 3P
799-601-2770 ECONO 4P
799-601-2780 ECONO 8P
799-601-2790 ECONO 12P
799-601-2810 DLI 8P
799-601-2820 DLI 12P
799-601-2830 DLI 16P
799-601-2840 Additional cable
799-601-2850 Case
799-601-7010 X 1P
799-601-7020 X 2P
799-601-7030 X 3P
799-601-7040 X 4P
799-601-7050 SWP 6P
799-601-7060 SWP 8P
799-601-7310 SWP 12P
799-601-7070 SWP 14P
799-601-7320 SWP 16P
799-601-7080 M 1P
799-601-7090 M 2P
799-601-7110 M 3P
799-601-7120 M 4P
799-601-7130 M 6P
799-601-7340 M 8P
20-256 PC750, 800-7

(1)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-7140 S 8P
799-601-7150 S 10P-White
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD24 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DEUTSCH 40P
799-601-9360 DEUTSCH 24P
799-601-9410 For NE, G sensor 2P
For fuel, boost
799-601-9420 3P
press.
799-601-9430 PVC socket 2P
PC750, 800-7 20-257

(1)
TROUBLESHOOTING WHEN ERROR CODE
"ELECTRICAL SYSTEM" AND FAILURE CODE
"MECHANICAL SYSTEM" ARE DISPLAYED
BEFORE CARRYING OUT TROUBLESHOOTING AFTER AN ERROR OR

A FAILURE CODE IS DISPLAYED ...................................................................................................... 20-304
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-306
Error Code in Electrical System E112 (Wiper Drive (For) S/C) ................................................................... 20-308
Error Code in Electrical System E113 (Wiper Drive (Rev) S/C) .................................................................. 20-312
Error Code in Electrical System E114 (Washer Drive S/C) ......................................................................... 20-314
Error Code in Electrical System E115 (Wiper Working Abnormality) .......................................................... 20-316
Error Code in Electrical System E116 (Wiper Parking Abnormality) ........................................................... 20-318
Error Code in Electrical System E117 (Eng. Controller S-NET Comm Err.)................................................ 20-322
Error Code in Electrical System E118 (Pump Controller S-NET Comm Err.).............................................. 20-324
Error Code in Electrical System E128 (Monitor Comm. Abnormality)......................................................... 20-326
Error Code in Electrical System E201 (CO Cancel Sol. S/C)...................................................................... 20-328
Error Code in Electrical System E202 (Travel Junction Sol. S/C) ............................................................... 20-330
Error Code in Electrical System E203 (Swing Brake Sol. S/C) ................................................................... 20-332
Error Code in Electrical System E204 (2-stage Relief Sol. S/C) ................................................................. 20-334
Error Code in Electrical System E205 (Swing Priority Sol. S/C) ................................................................. 20-336
Error Code in Electrical System E206 (Travel Speed Sol. S/C).................................................................. 20-338
Error Code in Electrical System E207 (Flash Light Relay S/C)................................................................... 20-340
Error Code in Electrical System E211 (CO Cancel Sol. Disc.).................................................................... 20-342
Error Code in Electrical System E212 (Travel Junction Sol. Disc.)............................................................. 20-344
Error Code in Electrical System E213 (Swing Brake Sol. Disc.) ................................................................. 20-346
Error Code in Electrical System E214 (2-stage Relief Sol. Disc.) ............................................................... 20-348
Error Code in Electrical System E215 (Swing Priority Sol. Disc.) ............................................................... 20-350
Error Code in Electrical System E216 (Travel Speed Sol. Disc.) ................................................................ 20-352
Error Code in Electrical System E217 (Model selection Abnormality) ........................................................ 20-354
Error Code in Electrical System E218 (S-Net Comm. Disc.)....................................................................... 20-356
Error Code in Electrical System E221 (Travel Alarm S/C) .......................................................................... 20-358
Error Code in Electrical System E224 (F Pump P. Sensor Abnormality) .................................................... 20-360
Error Code in Electrical System E225 (R Pump P. Sensor Abnormality) .................................................... 20-362
Error Code in Electrical System E226 (Press. Sensor Power Abnormality)................................................ 20-364
Error Code in Electrical System E227 (Engine Speed Sensor Abnormality) .............................................. 20-366
Error Code in Electrical System E232 (TVC Sol. S/C) ................................................................................ 20-368
Error Code in Electrical System E233 (TVC Sol. Disc.) .............................................................................. 20-370
Error Code in Electrical System E257 (Pump Comm. Abnormality) ........................................................... 20-372
Error Code in Electrical System E302 (Step Light Relay S/C) .................................................................... 20-374
Error Code in Electrical System E304 (Step Light Power Hold Relay S/C) ................................................ 20-376
Error Code in Electrical System E315 (Battery Relay Drive S/C) ............................................................... 20-378
Error Code in Electrical System E91B (Engine Ne sensor problem) .......................................................... 20-380
Error Code in Electrical System E91C (Engine G sensor problem) ............................................................ 20-381
Error Code in Electrical System E920 (Engine type selection error)........................................................... 20-382
Error Code in Electrical System E921 (Engine type mismatch) .................................................................. 20-384
Error Code in Electrical System E931 (Fuel dial sys. error)........................................................................ 20-386
Error Code in Electrical System E934 (Engine coolant sensor Hi error)..................................................... 20-388
Error Code in Electrical System E936 (Engine oil press. sw. error) ............................................................ 20-390
Error Code in Electrical System E93C (Engine boost sensor error) ........................................................... 20-392
PC750, 800-7 20-301

(1)
TROUBLESHOOTING
Error Code in Electrical System E93D (Engine fuel temp. sensor error) .................................................... 20-394
Error Code in Electrical System E953 (Engine Comm. Abnormality).......................................................... 20-396
Error Code in Electrical System E954 (Short engine starter sw.)................................................................ 20-398
Error Code in Electrical System E955 (Engine S-NET error) ...................................................................... 20-400
Error Code in Electrical System E956 (Engine power failure (1)) ............................................................... 20-402
Error Code in Electrical System E957 (Engine power failure (2)) ............................................................... 20-404
Error Code in Electrical System E95A (Engine Q-adj. sw. signal error) ...................................................... 20-406
Error Code in Electrical System E96A (Engine coolant sensor Lo error).................................................... 20-408
Error Code in Electrical System E970 (PCV1 over current)........................................................................ 20-410
Error Code in Electrical System E971 (PCV2 over current)........................................................................ 20-412
Error Code in Electrical System E974 (PCV1 line cut)................................................................................ 20-414
Error Code in Electrical System E975 (PCV2 line cut)................................................................................ 20-416
Error Code in Electrical System E977 (Rail press. sensor error) ................................................................ 20-418
Error Code in Electrical System E979 (Rail press. high)............................................................................. 20-420
Error Code in Electrical System E97A (Rail press. abnormal) .................................................................... 20-420
Error Code in Electrical System E97B (Rail press. low).............................................................................. 20-421
Error Code in Electrical System E97C (Rail press. too low) ....................................................................... 20-423
Error Code in Electrical System E97D (Rail press. out of control) .............................................................. 20-423
Error Code in Electrical System E980 (Eng. Controller Abnormality) ......................................................... 20-424
Error Code in Electrical System E981 (Fuel Injector 1 Disc.)...................................................................... 20-426
Error Code in Electrical System E98A (Fuel Injector 1 – 3 S/C) ................................................................. 20-432
Error Code in Electrical System E98B (Fuel Injector 4 – 6 S/C) ................................................................. 20-434
Failure Code in Mechanical System A000N1 (Eng. Hi Out of Std) ............................................................. 20-437
Failure Code in Mechanical System AA10NX (Aircleaner Clogging) .......................................................... 20-438
Failure Code in Mechanical System AB00KE (Charge Voltage Low) ......................................................... 20-440
Failure Code in Mechanical System B@BAZG (Eng. Oil Press. Low)........................................................ 20-442
Failure Code in Mechanical System B@BAZK (Eng. Oil Level Low).......................................................... 20-444
Failure Code in Mechanical System B@BCNS (Eng. Water Overheat)...................................................... 20-445
Failure Code in Mechanical System B@BCZK (Eng. Water Lvl Low)......................................................... 20-446
Failure Code in Mechanical System B@HANS (Hydr. Oil Overheat).......................................................... 20-448
Failure Code in Mechanical System DA80MA (Auto. Lub Abnormal.) ........................................................ 20-450
20-302 PC750, 800-7

(1)
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE
BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED

CODE
Connection table of circuit breakers
a This connection table shows the devices to which each power supply of the circuit breakers supplies power
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting for a displayed code, you should check the circuit breakers to see if the
power is supplied normally.
Type of power Circuit breaker Circuit breaker

Destination of power
supply No. capacity
1 40A Fuse box (Fuses No. 1 – 15)
Switch power supply 2 20A Boom working lamp, right head lamp
(Battery relay 3 20A Grease pump
terminal M) 4 20A Pump controller power source
5 20A Head lamp on cab
Constant power 6 20A Starting switch and engine controller (Power supply control)
supply 7 20A Engine controller (Power supply drive)
(Battery relay 8 20A Monitor panel
terminal B) 9 20A Fuse box (Fuses No. 16 – 20)
20-304 PC750, 800-7

(1)
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE
Connection table of fuse boxes

a This connection table shows the devices to which each power supply of the fuse boxes supplies power (A
switch power supply is a device which supplies power while the starting switch is at the ON position and a
constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting for a displayed code, you should check the fuse boxes to see if the
Type of power
Fuse No. Fuse capacity Destination of power
supply
TVC solenoid (for emergency pump drive)
1 10A
Swing holding brake solenoid (for swing brake release)
Starting motor cut-out relay
2 10A Machine push-up solenoid
Switch power supply Boom shockless solenoid
(Circuit breaker 1) 3 10A PPC lock solenoid
Cigarette lighter
4 20A
Windshield washer motor
Horn
5 10A
Flash light
6 10A (Spare)
7 10A Rotary lamp
Switch power supply
8 10A (Spare)
(Circuit breaker 1)
9 10A Radio
10 20A Monitor panel
11 25A Air conditioner unit
12 20A (Spare)
Switch power supply
13 20A (Spare)
(Circuit breaker 1)
14 10A Service power supply (M32 connector)
15 10A DC/DC converter
16 10A Radio
17 10A —
Constant power 18 10A (Engine compartment lamp)
supply 19 10A Room lamp
(Circuit breaker 9) Step light
20 10A Pump controller power source (for step light)
Step light switch
PC750, 800-7 20-305

(1)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-
tents fully before proceeding to actual troubleshooting work.
User Code Error Code Failure Code

Failure
Display in Display in Display in Title of failure phenomenon shown in failure history
phenomenon
monitor panel monitor panel monitor panel
Failure content Failure status as detected by monitor panel or controller
Response from
Action taken by the monitor panel or controller to protect an affected system or equipment, when they
monitor panel
detect some failure.
or controller
Phenomenon
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or
occurring on
controller
machine
Relative
Information on the failure occurred as well as the troubleshooting
information
Cause Standard value in normalcy and references for troubleshooting

<Content Included>
• Standard value in normalcy by which to pass "Good" or "No good" judgement over
the presumed cause
1
• Reference for passing the above "Good" or "No Good" judgement
<Phenomenon of Wiring Harness Failure>

• Disconnection
There is a faulty contact at the connector or disconnection of wiring harness
occurred.
2 • Defective grounding
A wiring harness that is not connected with a grounding circuit has a contact with
standard value in normalcy
the grounding circuit.

Presumed cause and
• Short-circuiting
Cause that presumably
A wiring harness that is not connected with a 24 V electric circuit has a contact
triggered failure
with the electric circuit.
in question
3
(The assigned No. is for
<Precaution for Troubleshooting>
filing purpose only. It
1) Connector No. display method and handling of T-adapter
does not stand for any
Insert or connect T-adapters in the following manner before starting troubleshoot-
priority)
ing unless otherwise instructed.
• If there is no indication of "male" or "female" in a specific connector No., discon-
4 nect the connector and insert the T-adapter into both male and female sides.
• If there is an indication of "male" or "female" in a specific connector No., discon-
nect the connector and connect the T-adepter with only one side of either "male"
or "female".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the
following manner unless otherwise instructed.
5 • Connect the positive (+) lead with the pin No. indicated at the front or the wiring
harness.
• Connect the negative (–) lead with the pin No. indicated at the front or the wiring
harness.
20-306 PC750, 800-7

(1)
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
PC750, 800-7 20-307

(1)
TROUBLESHOOTING E112
Error Code in Electrical System E112 (Wiper Drive (For) S/C)
Double-wiper specification
User Code Error Code Failure Code Failure Wiper Drive (For) S/C
— E112 DY2DKB phenomenon (Monitor panel system)
• Abnormal current flowed in the wiper motor forward rotation circuit, when power is supplied to the cir-
Failure content
cuit.
Response from
• Power to the wiper motor forward rotation circuit is switched OFF.
monitor panel
Phenomenon
occurring on • The wiper stops.
machine
Relative
information

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Upper wiper motor position during the troubleshooting.
defective W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between (3) and (1) Continued
Between (3) and grounding Above 1 Mz
Lower wiper motor position during the troubleshooting.
2
position during the troubleshooting.
Assembled-type diode
3 D06 defective D06 (male) Resistance value (Continuitiy)

Presumed cause and
(Internal short-circuiting) Between (1) and (5) Above 1 Mz (No continuitiy)

Between (2) and (6) Above 1 Mz (No continuitiy)
Grounding fault of wiring Between wiring harness between P01 (female) (9) and
Resistance
harness W04 (male) (3) or between P01 (female) (9) and D06 Above 1 Mz
4 value
(Contact with grounding (female) (1) and grounding
circuit) Between wiring harness between P01 (female) (10), J04
Resistance
and W05 (male) (3) or between P01 (female) (10) and Above 1 Mz
value
D06 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Monitor panel defective P01 Upper wiper switch Voltage
(Upper wiper motor)
OFF Below 3 V
Between (9) and grounding
ON 20 – 30 V (Note)
5
Monitor panel defective P01 Lower wiper switch Voltage
(Lower wiper motor)
OFF Below 3 V
ON 20 – 30 V (Note)
NOTE: When the upper wiper and lower wiper are operated simultaneously: Below 3 V 20 – 30 V (at regu-
lar intervals)
20-308 PC750, 800-7

(1)
Circuit diagram related to wiper motor (Double-wiper specification)
PC750, 800-7 20-309

(1)
Single-wiper specification
User Code Error Code Failure Code Failure Wiper Drive (For) S/C
— E112 DY2DKB phenomenon (Monitor panel system)
• Abnormal current flowed in the wiper motor forward rotation circuit, when power is supplied to the cir-
Failure content
cuit.
Response from
• Power to the wiper motor forward rotation circuit is switched OFF.
monitor panel
Phenomenon
machine
Relative
information

Windshield wiper motor position during the troubleshooting.
1

Presumed cause and

Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) (9) and Resistance
circuit) Above 1 Mz
W04 (male) (3) and grounding value
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Below 3 V
Between (9) and grounding Below 3 V 20 – 30 V
ON
(at constant cycle)
20-310 PC750, 800-7

(1)
Electric Circuit Diagram for Windshield Wiper Motor (Single wiper spec.)
PC750, 800-7 20-311

(1)
Error Code in Electrical System E113 (Wiper Drive (Rev) S/C)
User Code Error Code Failure Code Failure Wiper Drive (Rev) S/C
— E113 DY2EKB phenomenon (Monitor panel system)
• Abnormal current flowed in the wiper motor reverse rotation circuit, when power is supplied to the cir-
Failure content
cuit.
Response from
• Power to the wiper motor reverse rotation circuit is switched OFF.
monitor panel
Phenomenon
machine
Relative
information

Windshield wiper motor position for the troubleshooting.
1

Presumed cause and

2
circuit) Above 1 Mz
W04 (male) (1) and grounding value
P01 Windshield wiper switch Voltage
OFF Below 3 V
Between (10) and
grounding Below 3 V 20 – 30 V
ON
(at constant cycle)
20-312 PC750, 800-7

(1)
Electric Circuit Diagram for Windshield Wiper Motor (Single wiper spec.)
PC750, 800-7 20-313

(1)
Error Code in Electrical System E114 (Washer Drive S/C)
User Code Error Code Failure Code Failure Washer Drive S/C
— E114 DY2CKB phenomenon (Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power
Failure content
was switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine
Relative
information

Window washer drive position for the troubleshooting.
1 motor defective
M28 (male) Resistance value
(Internal short-circuiting)
Between (1) and (2) 5 – 20 z
Presumed cause and
Short-circuiting of wiring position during the troubleshooting.
harness
2 Between wiring harness from P01 (female) (3) and M28
(Contact with 24 V
circuit) (female) (2), or between wiring harness between P01 Voltage Below 1 V
(female) (3) and D05 (female) (7) and grounding
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
ON Below 1 V
20-314 PC750, 800-7

(1)
Electrical Circuit Diagram for Window Washer Motor
PC750, 800-7 20-315

(1)
Error Code in Electrical System E115 (Wiper Working Abnormality)
User Code Error Code Failure Code Failure Wiper Working Abnormality
— E115 DY20KA phenomenon (Monitor Panel system)
Failure content • A W signal is not inputted at both ends of movement, when it is in motion.
Response from
• Power to the windshield wiper motor is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper motor does not work.
machine
Relative • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
information (Code No.: 04502 Monitor input 3)

Windshield wiper motor W04 (female) Windshield wiper blade Resistance value
1 defective At upper end of operation
(Internal disconnection) Below 1 z
range
Between (6) and (5)
Outside upper end of
Above 1 Mz
operation range
Presumed cause and
Disconnection of wiring position during the troubleshooting.
harness Wiring harness between P01 (female) (5) and W04 Resistance
2 Below 1 z
(Disconnection or faulty (male) (6) value
contact with connector) Resistance
Wiring harness between W04 (male) (5) and grounding Below 1 z
value
P01 Windshield wiper blade Voltage
3 Monitor panel defective At upper end of
Below 1 V
operation range
Outside upper end of
20 – 30 V
operation range
20-316 PC750, 800-7

(1)
Windshield Wiper Motor Electrical Circuit Diagram (Single wiper spec.)
PC750, 800-7 20-317

(1)
Error Code in Electrical System E116 (Wiper Parking Abnormality)
User Code Error Code Failure Code Failure Wiper Parking Abnormality
— E116 DY20MA phenomenon (Monitor Panel system)
Failure content • P signal on the retraction range is not inputted, when the wiper is retracted.
Response from
• Power supply to the windshield wiper motor is switched OFF, when the wiper is retracted.
Monitor Panel
Phenomenon
occurring on • The windshield wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No.: 04502 Monitor input 3)

Upper windshield wiper
1 motor defective W04 (female) Wiper blade Resistance value
(Internal disconnection) Retraction range Below 1 z
Between (4) and (5)
Operation range Above 1 Mz
Lower windshield wiper
2 motor defective W05 (female) Wiper blade Resistance value
Between (4) and (5)
Presumed cause and

Wiring harness between P01 (female) (12) and W04 Resistance
Disconnection of wiring Below 1 z
(male) (4) value
harness
Resistance
3 (Disconnection or defec- Wiring harness between W04 (male) (5) and grounding Below 1 z
value
tive contact with connec-
tor) Wiring harness between P01 (female) (5) and W05 Resistance
Below 1 z
(male) (4) value
Resistance
value
P01 Upper wiper blade Voltage
Between (12) and Retraction range Below 1 V
4 Monitor panel defective grounding Operation range 20 – 30 V
P01 Lower wiper blade Voltage
Retraction range Below 1 V
Operation range 20 – 30 V
20-318 PC750, 800-7

(1)
Windshield Wiper Motor Electrical Diagram (Double wiper spec.)
PC750, 800-7 20-319

(1)
User Code Error Code Failure Code Failure Wiper Parking Abnormality
— E116 DY20MA phenomenon (Monitor Panel system)
Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is
Monitor Panel retracted.
Phenomenon
occurring on • The windshield wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No.: 04502 Monitor Input 3)

Windshield wiper motor
1 defective W04 (female) Windshield wiper blade Resistance value
Between (4) and (5)

Presumed cause and
harness
2 (Disconnection or defec- Below 1 z
(male) (4) value
tor) Resistance
Between wiring harness W04 (male) (5) and grounding Below 1 z
value
3 Monitor panel defective P01 Windshield wiper blade Voltage
Between (12) and Retraction range Below 1V
grounding Operation range 20 – 30 V
20-320 PC750, 800-7

(1)
Windshield Wiper Motor Electrical Circuit Diagram (Single wiper spec.)
PC750, 800-7 20-321

(1)
Error Code in Electrical System E117 (Eng. Controller S-NET Comm Err.)
User Code Error Code Failure Code Failure Eng. Controller S-NET Comm Err.
— E117 DAC0KR phenomenon (Monitor Panel System)
• The monitor panel detected communication failure in the S-NET communication circuit to the engine
Failure content
controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%.
monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The output lowers (The pump absorption torque is reduced).
occurring on
• If the working load increases, the engine may stall.
machine
Relative • Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
information (Code No. 05100: Connection of S-NET)

Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
1 (Disconnection or defec- Wiring harness between P02 (female) (9), (10) and E12
tive contact with connec- Resistance
(female) (21), (31) or between P02 (female) (9), (10) Below 1 z
tor) value
and C02 (female) (21)
Grounding fault of wiring position during the troubleshooting.
harness Between wiring harness between P02 (female) (9), (10)
2
(Contact with grounding and E12 (female) (21), (31) or between P02 (female) Resistance
circuit) Above 1 Mz
Presumed cause and
(9), (10) and C02 (female) (21) and related circuits and value
grounding
Short-circuiting of wiring
3 harness Between wiring harness between P02 (female) (9), (10)
(Contact with 24 V circuit) and E12 (female) (21), (31) or between P02 (female) Voltage Below 1 V
(9), (10) and C02 (female) (21) and related circuits and
grounding
Engine controller position during the troubleshooting.
4
defective E12 Voltage
Between (21), (31) and (11) 6–9V
P02 Voltage
Between (9), (10) and (20) 6–9V
20-322 PC750, 800-7

(1)
Circuit diagram related to S-NET communication
PC750, 800-7 20-323

(1)
Error Code in Electrical System E118 (Pump Controller S-NET Comm Err.)
User Code Error Code Failure Code Failure Pump Controller S-NET Comm Err.
— E118 DAB0KR phenomenon (Monitor panel System)
• The monitor panel detected communication failure in the S-NET communication circuit to the pump
Failure content
controller.
Phenomenon
occurring on
machine

tor) value
2
circuit) Above 1 Mz
Presumed cause and
(9), (10) and C02 (female) (21) and related circuits and value
grounding
(9), (10) and C02 (female) (21) and related circuits and
grounding
Pump controller position during the troubleshooting.
4
defective C02 Voltage
Between (21) and (31) 6–9V
P02 Voltage
Between (9), (10) and (20) 6–9V
20-324 PC750, 800-7

(1)
PC750, 800-7 20-325

(1)
Error Code in Electrical System E128 (Monitor Comm. Abnormality)
User Code Error Code Failure Code Failure Monitor Comm. Abnormality
E0E E128 DAF0MC phenomenon (Monitor panel system)
• The monitor panel detected communication failure in the CAN communication circuit to the engine con-
Failure content
troller or pump controller.
Phenomenon
occurring on
machine
Relative
information

Disconnection of wiring
Wiring harness between P70 (female) (16) and E12
harness Resistance
(female) (22) or between P70 (female) (16) and C02 Below 1 z
1 (Disconnection or defec- value
(female) (22)
tor) Wiring harness between P70 (female) (15) and E12
Resistance
value
(female) (32)
Between wiring harness between P70 (female) (16) and
Grounding fault of wiring E12 (female) (22) or between P70 (female) (16) and Resistance
Above 1 Mz
harness C02 (female) (22) or between P70 (female) (16) and value
2
(Contact with grounding related circuits and grounding

Presumed cause and
circuit) Between wiring harness between P70 (female) (15) and

E12 (female) (32) or between P70 (female) (15) and Resistance
Above 1 Mz
C02 (female) (32) or between P70 (female) (15) and value
related circuits and grounding
E12 (female) (22) or between P70 (female) (16) and
Short-circuiting of wiring Voltage Below 1 V
C02 (female) (22) or between P70 (female) (16) and
3 harness
(Contact with 24 V circuit)
Voltage Below 1 V
CAN terminal resistor position during the troubleshooting.
4
defective K30 (male), K31 (male) Voltage
Between (1) and (2) 40 – 80 z
Monitor panel, engine If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller
5 controller, or pump may be defective. (Since trouble is in those devices, troubleshooting cannot be car-
controller defective ried out.)
20-326 PC750, 800-7

(1)
Circuit diagram related to CAN communication
PC750, 800-7 20-327

(1)
Error Code in Electrical System E201 (CO Cancel Sol. S/C)
User Code Error Code Failure Code Failure CO Cancel Sol. S/C
— E201 DW48KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the CO cancel circuit, when power was supplied to the circuit.
• Power supply to the CO cancel circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
• When the boom is raised (in the heavy lift mode) and the machine travels, power is low (The pump CO
occurring on
function cannot be cancelled).
machine
Relative • Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02300: Solenoid 1)

CO cancel solenoid position during the troubleshooting.
defective V07 (male) Resistance value
1
or grounding fault) Between (1) and (2) 20 – 60 z
Between (2) and grounding Min. 1 Mz
Assembled-type diode position during the troubleshooting.

Presumed cause and
2 D03 defective
D03 (male) Resistance value (Continuitiy)
Between (1) and (5) Min. 1 Mz (No continuitiy)
harness
3 Between wiring harness between C03 (female) (17),
(Contact with grounding Resistance
circuit) J06, and V07 (female) (2) or between C03 (female) (17) Min. 1 Mz
value
and D03 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
Working mode
Pump controller C03 Voltage
4 Control lever
defective
At E mode +
Between (17) and Max. 1 V
all levers in neutral
grounding
At A mode (Note) 20 – 30 V
Note: You may carry out troubleshooting while the working mode is at E-mode and the travel lever is operated
or while the working mode is at E-mode and the heavy lift switch is turned ON.
20-328 PC750, 800-7

(1)
Electric circuit diagram related to CO cancel solenoid
PC750, 800-7 20-329

(1)
Error Code in Electrical System E202 (Travel Junction Sol. S/C)
User Code Error Code Failure Code Failure Travel Junction Sol. S/C
Failure content • Abnormal current flowed in the travel junction solenoid circuit, when power is supplied to the circuit.
• Power to the travel junction solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• When the right and left travel motors and work equipment are operated simultaneously, the machine
occurring on
deviates (The right and left travel circuits are not connected to each other).
machine
Relative • Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function.

Travel junction solenoid position during the troubleshooting.
1

Presumed cause and
2 D03 defective (Internal

short-circuiting)
harness
3 Between wiring harness between C03 (female) (7), J06,
circuit) and V03 (female) (2) or between C03 (female) (7) and Above 1 Mz
value
Travel lever and work
C03 Voltage
4 Pump controller defective equipment control lever
All levers in neutral Below 1 V
Between (7) and grounding Straight travel + Operation
20 – 30 V
of work equipment
20-330 PC750, 800-7

(1)
Electric circuit diagram related to travel junction solenoid
PC750, 800-7 20-331

(1)
Error Code in Electrical System E203 (Swing Brake Sol. S/C)
User Code Error Code Failure Code Failure Swing Brake Sol. S/C
E03 E203 DW45KB phenomenon (Pump controller system)
• Abnormal current flowed in the swing holding brake solenoid circuit, when power is supplied to the cir-
Failure content
cuit.
• Power to the swing holding brake solenoid circuit is switched OFF.
Response from
controller
Phenomenon
occurring on • The machine cannot swing (The swing holding brake cannot be released).
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 02300: Solenoid 1)
Relative
• If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding
information
brake release switch in the RELEASE position (The parking brake does not operate when the machine
stops, however).

Swing holding brake position during the troubleshooting.
solenoid defective V04 (male) Resistance value
1
2 D03 defective

Presumed cause and

harness Between wiring harness between C03 (female) (37),
3
(Contact with grounding D01, J02, X05, J06, and V04 (female) (2) or between Resistance
circuit) Above 1 Mz
C03 (female) (37) and S25 (female) (8) or between C03 value
Work equipment
C03 Voltage
control lever
4 Pump controller defective Max. 1 V
All levers in neutral (5 sec after setting
Between (37) and in neutral)
grounding
Work equipment or
20 – 30 V
swing operated
20-332 PC750, 800-7

(2)
Electric circuit diagram related to swing holding brake
PC750, 800-7 20-333

(1)
Error Code in Electrical System E204 (2-stage Relief Sol. S/C)
User Code Error Code Failure Code Failure 2-stage Relief Sol. S/C
— E204 DWK0KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• The heavy-lift function does not work.
occurring on
• Travel power is low (The main relief valve is not set in the HIGH PRESSURE position).
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

2-stage relief solenoid position during the troubleshooting.
1
Presumed cause and

2 D03 defective
harness
value
4 Pump controller defective C03 Travel control lever Voltage
Between (28) and NEUTRAL Max. 1 V
grounding Travel operation 20 – 30 V
20-334 PC750, 800-7

(1)
Electric circuit diagram related to 2-stage relief solenoid
PC750, 800-7 20-335

(1)
Error Code in Electrical System E205 (Swing Priority Sol. S/C)
User Code Error Code Failure Code Failure Swing Priority Sol. S/C
Failure content • Abnormal current flew to the swing priority solenoid, when power was supplied to the circuit.
• Power supply to the swing priority solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• When the boom is raised and the machine is swung simultaneously in the swing priority mode, the swing
occurring on
speed is low (the oil flow in the swing circuit is kept low).
machine
Relative • Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function.

Swing priority solenoid position during the troubleshooting.
1
2 D04 defective
Presumed cause and
harness
value
Swing priority switch
C03 Left work equipment Voltage
Pump controller control lever
4
defective
OFF + NEUTRAL Max. 1 V
Between (38) and Swing priority mode
grounding + 20 – 30 V
Swing operation
20-336 PC750, 800-7

(1)
Electric circuit diagram related to swing priority solenoid
PC750, 800-7 20-337

(1)
Error Code in Electrical System E206 (Travel Speed Sol. S/C)
User Code Error Code Failure Code Failure Travel Speed Sol. S/C
Failure content • Abnormal current flew to the travel speed solenoid, when power was supplied to the circuit.
• Power supply to the travel speed solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The swash plate angle of the travel motor is not minimized.)
machine
• The travel speed shifting solenoid is not turned ON when the engine speed is below 1,200 rpm.
Relative
• Operation of the travel speed solenoid (ON or OFF) can be checked in the monitoring function.
information

Travel speed solenoid position during the troubleshooting.
1
Presumed cause and

2 D04 defective
harness
value
a Turn the engine starting switch OFF for the preparations, and hold it in high idling
during the troubleshooting.
4 Pump controller defective C03 Travel speed switch Voltage
Between (27) and Lo Max. 1 V
grounding Hi 20 – 30 V
20-338 PC750, 800-7

(1)
Electric circuit diagram related to travel speed solenoid
PC750, 800-7 20-339

(1)
Error Code in Electrical System E207 (Flash Light Relay S/C)
User Code Error Code Failure Code Failure Flash Light Relay S/C
— E207 D163KB phenomenon (Pump controller system)
• Abnormal current flowed in the flash light relay circuit (the primary circuit of the relay), when power is
Failure content
supplied to the circuit.
• The controller turns OFF the output to the coil circuit of the flash light relay.
Response from
controller
Phenomenon
occurring on • The flash light does not flash.
machine
• Operation of the flash light relay circuit (the primary side of the relay) (ON or OFF) can be checked in
Relative the monitoring function. (Code No. 03701: Controller output 2)
information • This error code detects abnormality on the primary (coil) side of the flash light relay and cannot detect
abnormality on the secondary (contact) side.

Flash light relay defective position during the troubleshooting.
1
(Internal short-circuiting) R21 (male) Resistance value
Between (1) and (2) 250 – 350 z

Presumed cause and
2
(Contact with grounding Between wiring harness between C03 (female) (25) and Resistance
circuit) Min. 1 Mz
R21 (female) (1) and grounding valve
C03 Horn switch Voltage
Pump controller
3 20 – 30 V Max. 1 V
defective
Between (25) and ON (at constant cycle,
grounding 5 seconds)
OFF Max. 1 V
20-340 PC750, 800-7

(1)
Electric circuit diagram related to horn and flash light relay
PC750, 800-7 20-341

(1)
Error Code in Electrical System E211 (CO Cancel Sol. Disc.)
User Code Error Code Failure Code Failure CO Cancel Sol. Disc.
— E211 DW48KA phenomenon (Pump controller system)
Failure content • No current flows to the CO cancel solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• When the boom is raised (in the heavy lift mode) and the machine travels, power is low (The pump CO
occurring on
function cannot be cancelled).
machine
• Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function.
Relative
• Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
information
solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or
OFF, refer to the troubleshooting under Error Code [E201].)

CO cancel position during the troubleshooting.
1 solenoid defective
V07 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z

Presumed cause and
harness
Wiring harness from C03 (female) (17) to J06 and V07 Resistance
2 (Disconnection or defec- Max. 1 z
(female) (2) value
tor) Wiring harness between V07 (female) (1) to J15 and Resistance
Max. 1 z
grounding value
3 harness Between wiring harness between C03 (female) (17),
(Contact with 24 V circuit) J06, and V07 (female) (2) or between C03 (female) (17) Voltage Max. 1 V
Pump controller position during the troubleshooting.
4
defective C03 (female) Resistance value
Between (17) and grounding 20 – 60 z
20-342 PC750, 800-7

(1)
Electric circuit diagram related to CO cancel solenoid
PC750, 800-7 20-343

(1)
Error Code in Electrical System E212 (Travel Junction Sol. Disc.)
User Code Error Code Failure Code Failure Travel Junction Sol. Disc.
Failure content • No current flows to the travel junction solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it).
Phenomenon
• When the right and left travel motors and work equipment are operated simultaneously, the machine
occurring on
deviates (The right and left travel circuits are not connected to each other).
machine
• Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information
OFF, refer to the troubleshooting under Error code [E202].)

Travel junction solenoid position during the troubleshooting.
1 defective
Between (1) and (2) 20 – 60 z

Presumed cause and
harness
Wiring harness between C03 (female) (7), J06, and V03 Resistance
(female) (2) value
tor) Wiring harness between V03 (female) (1), J15, and Resistance
Max. 1 z
grounding value
3 harness
(Contact with 24 V circuit) Between wiring harness between C03 (female) (7), J06, Voltage Below 1 V
V03 (female) (2), and D03 (female) (3) and grounding
4 Pump controller defective
C03 (female) Resistance value
20-344 PC750, 800-7

(1)
Electric circuit diagram related to travel junction solenoid
PC750, 800-7 20-345

(1)
Error Code in Electrical System E213 (Swing Brake Sol. Disc.)
User Code Error Code Failure Code Failure Swing Brake Sol. Disc.
E03 E213 DW45KA phenomenon (Pump controller system)
Failure content • No current flows in the swing holding brake solenoid circuit, when power is supplied to the circuit.
Phenomenon
occurring on • The machine cannot swing (The swing holding brake cannot be released).
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
• If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding
brake release switch in the RELEASE position (The parking brake does not operate when the machine
Relative stops, however).
information • Keep the swing lock switch in the OFF position and the swing holding brake release switch in the
RELEASE position during troubleshooting.
OFF, refer to the troubleshooting under Error code [E203].)

Swing holding brake position during the troubleshooting.
1 solenoid defective
Between (1) and (2) 20 – 60 z
2 D01 defective
D01 (male) Digital tester Continuity
Between (7) and (3) Diode mode Continued
Swing lock switch
3 defective X05 (female) Swing lock switch Resistance value
OFF Max. 1 z
Between (3) and (4)
Presumed cause and
LOCK Min. 1 Mz
Wiring harness between C03 (female) (37) and D01 Resistance
Disconnection of wiring Max. 1 z
(female) (7) value
harness
Wiring harness between D01 (female) (3), J02, and X05 Resistance
(male) (3) value
tor) Wiring harness between X05 (male) (4), J06, and V04 Resistance
Max. 1 z
(female) (2) value
Wiring harness between V04 (female) (1), J15, and Resistance
Max. 1 z
grounding value
5 harness
(Contact with 24 V circuit) Between wiring harness between C03 (female) (37) and Voltage Max. 1 V
D01 (female) (7)
6 Pump controller defective C03 (female) Disconnect D01 and Resistance value
Between (37) and directly connect pins (3)
and (7) on the female side. 20 – 60 z
grounding
20-346 PC750, 800-7

(2)
Electric circuit diagram related to swing holding brake solenoid
PC750, 800-7 20-347

(1)
Error Code in Electrical System E214 (2-stage Relief Sol. Disc.)
User Code Error Code Failure Code Failure 2-stage Relief Sol. Disc.
— E214 DWK0KA phenomenon (Pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
Phenomenon
• The heavy-lift function does not work.
occurring on
• Travel power is low (The main relief valve is not set in the HIGH PRESSURE position).
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information

2-stage relief solenoid position during the troubleshooting.
1 defective
Between (1) and (2) 20 – 60 z

Presumed cause and
harness
(female) (2) value
Max. 1 z
grounding value
20-348 PC750, 800-7

(1)
Electric circuit diagram related to 2-stage relief solenoid
PC750, 800-7 20-349

(1)
Error Code in Electrical System E215 (Swing Priority Sol. Disc.)
User Code Error Code Failure Code Failure Swing Priority Sol. Disc.
Failure content • No current flows to the swing priority solenoid circuit, when power is supplied to the circuit.
Phenomenon
• When the boom is raised and the machine is swung simultaneously in the swing priority mode, the
occurring on
swing speed is low (the oil flow in the swing circuit is kept low).
machine
• Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information

Swing priority solenoid position during the troubleshooting.
1 defective
Between (1) and (2) 20 – 60 z

Presumed cause and
harness
(female) (2) value
Max. 1 z
grounding value
Pump controller running during the troubleshooting.
4
defective C03 (female) Resistance value
20-350 PC750, 800-7

(1)
Electric circuit diagram related to swing priority solenoid
PC750, 800-7 20-351

(1)
Error Code in Electrical System E216 (Travel Speed Sol. Disc.)
User Code Error Code Failure Code Failure Travel Speed Sol. Disc.
Failure content • No current flows to the travel speed solenoid circuit, when power is supplied to the circuit.
Phenomenon
• The travel speed does not shift to Hi.
occurring on
(The swash plate angle of the travel motor is not minimized.)
machine
• The travel speed shifting solenoid is not turned ON when the engine speed is below 1,200 rpm.
• Operation of the travel speed solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 02300: Solenoid 1)
information • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the

Travel speed solenoid position during the troubleshooting.
1 defective
Between (1) and (2) 20 – 60 z

Presumed cause and
harness
(female) (2) value
Max. 1 z
grounding value
20-352 PC750, 800-7

(1)
Electric circuit diagram related to travel speed solenoid
PC750, 800-7 20-353

(1)
Error Code in Electrical System E217 (Model selection Abnormality)
User Code Error Code Failure Code Failure Model selection Abnormality
— E217 DA2SKQ phenomenon (Pump controller system)
Failure content • A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC750).
Response from
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • None in particular with PC750 • 800 model
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
Relative function. (Code No. 00200: Controller Model Code)
information a Input of model selecting signals (ON or OFF) can be confirmed in the monitoring function.
(Code No. 02201: Switch Input 2)

Model selecting connec- position during the troubleshooting.
tor defective C09 (female) Resistance value
1
(Internal disconnection or
short-circuiting) Between (1) , (3), (4) and (8) Min. 1 Mz
Between (2) and (8) Max. 1 z
harness
Wiring harness between C02 (female) (27) and C09 Resistance

(male) (2) value
Presumed cause and

tor) Between wiring harness between C09 (male) (8) to J05 , Resistance
Max. 1 z
J22 and grounding value
Grounding fault of wiring Between wiring harness between C02 (female) (37) and Resistance
Min. 1 Mz
harness C09 (male) (1) value
3
circuit) Min. 1 Mz
C09 (male) (3) and grounding value
Between wiring harness between C02 (female) (7) and Resistance
Min. 1 Mz
C09 (male) (4) and grounding value
4 Pump controller defective C02 Voltage
Between (7), (17), (37) and grounding 20 – 30 V
Between (27) and grounding Max. 1 V
20-354 PC750, 800-7

(1)
Electric circuit diagram related to model selection connector (for pump controller)
PC750, 800-7 20-355

(1)
Error Code in Electrical System E218 (S-Net Comm. Disc.)
User Code Error Code Failure Code Failure S-Net Comm. Disc.
E0E E218 DA2SKA phenomenon (Pump controller system)
• The pump controller detected communication failure in the S-NET communication circuit to the monitor
Failure content
panel or engine controller.
Phenomenon
occurring on
machine

(female) (21), (31) or between P02 (female) (9), (10) Max. 1 z
tor) value
2
circuit) Min. 1 Mz
(9), (10) and C02 (female) (21) or between P02 (female) value
(9), (10) and related circuits and grounding
Presumed cause and

(Contact with 24 V circuit) and E12 (female) (21), (31) or between P02 (female) Voltage Max. 1 V
(9), (10) and C02 (female) (21) or between P02 (female)
P02 Voltage
Between (9), (10) and (20) 6–9V
5
Between (21), (31) and (11) 6–9V
C02 Voltage
20-356 PC750, 800-7

(1)
Electrical Circuit Diagram for S-NET Communication
PC750, 800-7 20-357

(1)
Error Code in Electrical System E221 (Travel Alarm S/C)
User Code Error Code Failure Code Failure Travel Alarm S/C
— E221 DV20KB phenomenon (Pump controller system)
Failure content • Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit.
• Power to the travel alarm circuit is switched OFF.
Response from
controller
Phenomenon
occurring on • The travel alarm does not sound.
machine
Relative • Operation of the travel alarm (ON or OFF) can be checked in the monitoring function.
information (Code No. 03701: Controller output 2)

F01 (female) Travel lever Voltage
Travel alarm defective
1 Neutral Max. 1 V
(Internal defect) Between (1) and (2)

Operated 20 – 30 V
Presumed cause and
If the above voltage is normal but the travel alarm does not operate, the travel alarm
is defective.
2
circuit) Min. 1 Mz
F01 (female) (1) and grounding value
3 Pump controller defective C03 Travel lever Voltage
Neutral Max. 1 V
20-358 PC750, 800-7

(1)
Circuit diagram related to travel alarm
PC750, 800-7 20-359

(1)
Error Code in Electrical System E224 (F Pump P. Sensor Abnormality)
User Code Error Code Failure Code Failure F Pump P. Sensor Abnormality
— E224 DHPAMA phenomenon (Pump controller system)
Failure content • Signal voltage from the front pump pressure sensor is below 0.3 V or above 4.42 V.
Response from
• When the failure cause disappears of itself, the machine operation returns to normalcy.
controller
Phenomenon
occurring on • The front pump pressure cannot be monitored (Special function of monitor panel).
machine
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure
Relative sensor will be broken. Accordingly, take extreme care when checking.
information • Input from the front pump pressure sensor (pressure) can be checked in the monitoring function.
(Code No. 01100: Front pump pressure)

Sensor power supply
1 If error code [226] is displayed, carry out troubleshooting for it first.
system defective
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
P30 Voltage
Front pump pressure
Between (B) and (A) Power supply 4.5 – 5.5 V
2 sensor defective
(Internal defect) Between (C) and (A) Signal 0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,
for another cause of the trouble, and then judge.
Disconnection of wiring Wiring harness between C01 (female) (22), J21, and Resistance
harness Max. 1 z
Presumed cause and
P30 (female) (B) value

3 (Disconnection or defec-
tive contact with connec- Wiring harness between C01 (female) (10), J08, and Resistance
Max. 1 z
tor) P30 (female) (A) value
Wiring harness between C01 (female) (8) and P30 Resistance
Max. 1 z
(female) (C) value
4
circuit) Min. 1 Mz
P30 (female) (C) and grounding value
Between wiring harness between C01 (female) (22),
5 harness Voltage Max. 1 V
J21, and P30 (female) (B) and grounding
Between wiring harness between C01 (female) (8) and
Voltage Max. 1 V
P30 (female) (C) and grounding
Between (22) and (10) 4.5 – 5.5 V
Between (8) and (10) 0.5 – 4.5 V
20-360 PC750, 800-7

(1)
Circuit diagram related to front pump pressure sensor
PC750, 800-7 20-361

(1)
Error Code in Electrical System E225 (R Pump P. Sensor Abnormality)
User Code Error Code Failure Code Failure R Pump P. Sensor Abnormality
— E225 DHPBMA phenomenon (Pump controller system)
Failure content • Signal voltage from the rear pump pressure sensor is below 0.3 V or above 4.42 V.
Response from
controller
Phenomenon
occurring on • The rear pump pressure cannot be monitored (Special function of monitor panel).
machine
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure
Relative sensor will be broken. Accordingly, take extreme care when checking.
information • Input from the rear pump pressure sensor (pressure) can be checked in the monitoring function.
(Code No. 01101: Rear pump pressure)

Sensor power supply
1 If error code [226] is displayed, carry out troubleshooting for it first.
system defective
P31 Voltage
Rear pump pressure
Between (B) and (A) Power supply 4.5 – 5.5 V
2 sensor defective
(Internal defect) Between (C) and (A) Signal 0.5 – 4.5 V
Disconnection of wiring Wiring harness between C01 (female) (22), J21, and Resistance
harness Max. 1 z
Presumed cause and
P31 (female) (B) value

tive contact with connec- Wiring harness between C01 (female) (10), J08, and Resistance
Max. 1 z
tor) P31 (female) (A) value
Wiring harness between C01 (female) (2) and P31 Resistance
Max. 1 z
(female) (C) value
4
circuit) Min. 1 Mz
P31 (female) (C) and grounding value
Between wiring harness between C01 (female) (22),
5 harness Voltage Max. 1 V
J21, and P31 (female) (B) and grounding
Voltage Max. 1 V
P31 (female) (C) and grounding
Between (22) and (10) 4.5 – 5.5 V
Between (2) and (10) 0.5 – 4.5 V
20-362 PC750, 800-7

(1)
Circuit diagram related to rear pump pressure sensor
PC750, 800-7 20-363

(1)
Error Code in Electrical System E226 (Press. Sensor Power Abnormality)
User Code Error Code Failure Code Failure Press. Sensor Power Abnormality
— E226 DA25KP phenomenon (Pump controller system)
Failure content • Abnormal current flowed in the pressure sensor power supply (5 V) circuit.
• Power to the power supply (5 V) circuit is switched OFF.
Response from
controller
Phenomenon
• The pressure sensor signal is not input normally.
occurring on
• The error code of abnormality in the pressure sensor is displayed, too.
machine
Relative
information

a Disconnect the connector when the engine starting switch is in OFF, and hold it in
the ON position during the troubleshooting.
Pressure sensor Disconnect the parts Front pump

Connector P30
1 defective shown at right in order. pressure sensor
(Internal short-circuiting) If the error code goes off
when one of those parts is Rear pump
disconnected, that part is Connector P31

pressure sensor
Presumed cause and
defective.
Grounding fault of wiring Between wiring harness between C01 (female) (22),
Resistance
harness J21, and P30 (female) (B) and grounding Min. 1 Mz
2 value
(Contact with grounding [Front pump pressure sensor system]
circuit) Between wiring harness between C01 (female) (22),
Resistance
J21, and P31 (female) (B) and grounding Min. 1 Mz
value
[Rear pump pressure sensor system]
C01 Voltage
Between (22) and (10) 4.5 – 5.5 V
20-364 PC750, 800-7

(1)
Circuit diagram related to pressure sensor power supply
PC750, 800-7 20-365

(1)
Error Code in Electrical System E227 (Engine Speed Sensor Abnormality)
User Code Error Code Failure Code Failure Engine Speed Sensor Abnormality
— E227 DLE2MA phenomenon (Pump controller system)
Failure content • Normal pulse signal is not input to the signal circuit of the engine speed sensor.
Response from • Control is carried out as in the E-mode.
Phenomenon
• Power is a little low (Engine speed cannot be sensed).
occurring on
• The monitor panel cannot monitor the engine speed (pump controller system).
machine
Relative • Input from the engine speed sensor (rpm) can be checked in the monitoring function.
information (Code No. 01006: Engine speed)

Engine speed sensor position during the troubleshooting.
defective ENE (male) Resistance value
1
or disconnection) Between (1) and (2) 300 – 1,000 z
Engine speed sensor
2 Refer to TESTING AND ADJUSTING, Adjusting engine speed sensor.
adjustment defective
Presumed cause and

harness
Wiring harness between C02 (female) (40) and ENE Resistance
(female) (1) value
tor) Wiring harness between C02 (female) (39) and ENE Resistance
Max. 1 z
(female) (2) value
4 harness
(Contact with 24 V circuit) Wiring harness between C02 (female) (40) and ENE Voltage Max. 1 V
(female) (1)
5 Pump controller defective C02 (female) Resistance value
Between (40) and (39) 300 – 1,000 z
Between (39), (40) and grounding Min. 1 Mz
20-366 PC750, 800-7

(1)
Electric circuit diagram related to engine speed sensor
PC750, 800-7 20-367

(1)
Error Code in Electrical System E232 (TVC Sol. S/C)
User Code Error Code Failure Code Failure TVC Sol. S/C
E02 E232 DXA0KB phenomenon (Pump controller system)
Failure content • Abnormal current flowed in the TVC solenoid circuit.
• Power to the TVC solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• If the pump load increases, the engine speed lowers extremely and the engine may stall. (The pump
occurring on
absorption torque cannot be controlled.)
machine
• Output to the TVC solenoid (current) can be checked in the monitoring function.
(Code No. 01300: TVC solenoid current)
Relative • If the solenoid and wiring harness are normal, the machine can be operated with the output equivalent
information to the E-mode by setting the emergency pump drive switch in the EMERGENCY position (Error code
[E233] is displayed at this time, but it does not indicate a failure).
• Keep the emergency pump drive switch in the normal position during troubleshooting.

TVC solenoid defective
1 (Internal short-circuiting C13 (male) Resistance value
Emergency pump drive

switch defective Emergency pump
Presumed cause and
2 S25 (male) Resistance value

(Internal short-circuiting drive switch
or grounding fault) Between (3) and (4) Above 1 Mz
NORML position
harness Between wiring harness between C03 (female) (16) and Resistance
3 Above 1 Mz
(Contact with grounding S25 (female) (3) and grounding value
circuit) Between wiring harness between S25 (female) (2) and Resistance
Above 1 Mz
C13 (female) (1) and grounding value
4 Pump controller defective C03 (female) Resistance value
Between (16) and (3) 10 – 22 z
20-368 PC750, 800-7

(1)
Electric circuit diagram related to TVC solenoid
PC750, 800-7 20-369

(1)
Error Code in Electrical System E233 (TVC Sol. Disc.)
User Code Error Code Failure Code Failure TVC Sol. Disc.
E02 E233 DXA0KA phenomenon (Pump controller system)
Failure content • No current flows in the TVC solenoid circuit.
Phenomenon
• If the pump load increases, the engine speed lowers extremely and the engine may stall.
occurring on
(The pump absorption torque cannot be controlled.)
machine
• Output to the TVC solenoid (current) can be checked in the monitoring function.
Relative (Code No. 01300: TVC solenoid current)
information • If the solenoid and wiring harness are normal, the machine can be operated with the output equivalent
to the E-mode by setting the emergency pump drive switch in the EMERGENCY position.

TVC solenoid defective position during the troubleshooting.
1
(Internal disconnection) C13 (male) Resistance value
Between (1) and (2) 10 – 22 z
Emergency pump
S25 (male) Resistance value
Emergency pump drive drive switch
2 switch defective NORML position Below 1 z
(Internal disconnection) Between (2) and (3)
EMERGENCY position Above 1 Mz
NORML position Below 1 z
Between (5) and (6)
EMERGENCY position Above 1 Mz

Presumed cause and
Wiring harness between C03 (female) (16) and S25 Resistance
(female) (3) value
harness
Wiring harness between S25 (female) (2) and C13 Resistance
(female) (1) value
tor) Wiring harness between C03 (female) (3) and S25 Resistance
Below 1 z
(female) (6) value
Wiring harness between S25 (female) (5) and C13 Resistance
Below 1 z
(female) (2) value
4 harness Voltage Below 1 V
S25 (female) (3) and grounding
Between wiring harness between S25 (female) (2) and
Voltage Below 1 V
C13 (female) (1) and grounding
Between (16) and (3) 10 – 22 z
20-370 PC750, 800-7

(1)
Electric circuit diagram related to TVC solenoid
PC750, 800-7 20-371

(1)
Error Code in Electrical System E257 (Pump Comm. Abnormality)
User Code Error Code Failure Code Failure Pump Comm. Abnormality
E0E E257 DA2RMC phenomenon (Pump controller system)
• The pump controller detected communication failure in the CAN communication circuit to the monitor
Failure content
panel or engine controller.
Phenomenon
occurring on
machine
Relative
information

harness Resistance
(female) (22)
Resistance
value
(female) (32)
Above 1 Mz
2

Presumed cause and

Above 1 Mz
3 harness
Voltage Below 1 V
4
defective K30 (male), K31 (male) Resistance value
Between (1) and (2) 40 – 80 z
Monitor panel, If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller
5 engine controller, or may be defective. (Since trouble is in those devices, troubleshooting cannot be car-
pump controller defective ried out.)
20-372 PC750, 800-7

(1)
PC750, 800-7 20-373

(1)
Error Code in Electrical System E302 (Step Light Relay S/C)
User Code Error Code Failure Code Failure Step Light Relay S/C
• Abnormal current flowed in the step light relay circuit (the primary circuit of the relay), when power is
Failure content
supplied to the circuit.
• Power to the step light relay circuit is switched OFF.
Response from
controller
Phenomenon
occurring on • Step light does not light up.
machine
• Operation of the step light relay circuit (the primary side of the relay) (ON or OFF) can be checked in
Relative the monitoring function. (Code No. 03701: Controller output 2)
information • This error code detects abnormality on the primary (coil) side of the step light relay and cannot detect
abnormality on the secondary (contact) side.

Step light relay defective position during the troubleshooting.
1
(Internal short-circuiting) R15 (male) Resistance value
Between (1) and (2) 250 – 350 z

Presumed cause and
2
circuit) Above 1 Mz
R15 (female) (1) and grounding value
C03 Step light switch Voltage
20 – 30 V
Between (15) and ON
(Kept for 60 sec)
grounding
OFF Below 1 V
20-374 PC750, 800-7

(1)
Electric circuit diagram related to step light
PC750, 800-7 20-375

(1)
Error Code in Electrical System E304 (Step Light Power Hold Relay S/C)
User Code Error Code Failure Code Failure Step Light Power Hold Relay S/C
• Abnormal current flowed in the step light power hold relay circuit (the primary circuit of the relay), when
Failure content
power is supplied to the circuit.
• Power to the step light power hold relay circuit is switched OFF.
Response from
controller
Phenomenon
occurring on • Step light does not light up.
machine
• Operation of the step light power hold relay circuit (the primary side of the relay) (ON or OFF) can be
Relative checked in the monitoring function. (Code No. 03701: Controller output 2)
information • This error code detects abnormality on the primary (coil) side of the step light power hold relay and can-
not detect abnormality on the secondary (contact) side.

Step light power hold position during the troubleshooting.
1 relay defective
R15 (male) Resistance value
Between (1) and (2) 250 – 350 z

Presumed cause and
harness
2 Between wiring harness between C03 (female) (5), D02,
circuit) and R14 (female) (1) or between C03 (female) (5) and Above 1 Mz
value
C03 Step light switch Voltage
20 – 30 V
ON
Between (5) and grounding (Kept for 60 sec)
OFF Below 1 V
20-376 PC750, 800-7

(1)
Electric circuit diagram related to step light
PC750, 800-7 20-377

(1)
Error Code in Electrical System E315 (Battery Relay Drive S/C)
User Code Error Code Failure Code Failure Battery Relay Drive S/C
Failure content • When a signal is output to the battery relay drive circuit, abnormal current flowed.
Response from • The controller turns OFF the output to the battery relay drive circuit.
Phenomenon
occurring on • There may be a trouble in writing data into the ROM (non-volatile memory) of each controller.
machine
Relative • Operation of the battery relay (ON or OFF) can be checked in the monitoring function.
information (Code No. 03700: Controller output 1)

Battery relay defective
1 (Internal short-circuiting Battery relay (Unit) Resistance value
or grounding fault) Between BR and E Approx. 100 z
Presumed cause and
Between BR and grounding Min. 1 Mz

harness Between wiring harness between C03 (female) (4), D01,
2
(Contact with grounding J01, battery relay terminal BR or between C03 (female) Resistance
circuit) Min. 1 Mz
(4) and starting switch terminal B or between C03 value
Pump controller
3 C03 (female) Starting switch Voltage
defective
20 – 30 V
Between (4) and grounding ON o OFF
(For 0.5 sec)
20-378 PC750, 800-7

(1)
Circuit diagram related to battery relay drive
PC750, 800-7 20-379

(1)
TROUBLESHOOTING E91B
Error Code in Electrical System E91B (Engine Ne sensor problem)
User Code Error Code Failure Code Failure Engine Ne sensor problem
E11 E91B DLE3LC phenomenon (Engine controller system)
Failure content • Cranking angle cannot be judged from the engine Ne speed sensor signal.
Response from • The machine is driven with limited output.
Phenomenon • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • The engine speed does not rise above low idling.
• Input from the engine Ne speed sensor (rpm) can be checked in the monitoring function.
Relative
(Code No. 01002: Engine speed)
information
• Special adapter (799-601-9410) is necessary for troubleshooting for the engine Ne speed sensor.

Engine Ne speed sensor position during the troubleshooting.
defective NE (male) Resistance value
1
short-circuiting) Between (1) and (2) 85 – 210 z
Between (1), (2) and grounding Above 1 Mz
harness
Wiring harness between E12 (female) (36) and NE Resistance
Presumed cause and

(female) (2) value
tor) Wiring harness between E12 (female) (26) and NE Resistance
Below 1 z
(female) (1) value
harness Between wiring harness between E12 (female) (36) and Resistance
3 Above 1 Mz
(Contact with grounding NE (female) (2) and grounding value
circuit) Between wiring harness between E12 (female) (26) and Resistance
Above 1 Mz
NE (female) (1) and grounding value
Engine controller E12 (female) Resistance value
4
defective
Between (36) and (26) 85 – 210 z
Circuit diagram related to engine Ne speed sensor
20-380 PC750, 800-7

(2)
TROUBLESHOOTING E91C
Error Code in Electrical System E91C (Engine G sensor problem)
User Code Error Code Failure Code Failure Engine G sensor problem
E11 E91C DLH1LC phenomenon (Engine controller system)
Failure content • Cylinder cannot be judged from the engine G speed sensor signal.
• The machine is driven with limited output.
Response from
• Control is carried out with the Ne speed sensor signal.
controller
Relative
• Special adapter (799-601-9410) is necessary for troubleshooting for the engine G speed sensor.
information

Engine G speed sensor position during the troubleshooting.
defective (Internal dis- G (male) Resistance value
1
connection or short-cir-
cuiting) Between (1) and (2) 1.4 k – 3.5 kz
harness
Wiring harness between E12 (female) (35) and G Resistance
Presumed cause and

(female) (2) value
tor) Wiring harness between E12 (female) (25) and G Resistance
Below 1 z
(female) (1) value
3 Above 1 Mz
(Contact with grounding G (female) (2) and grounding value
Above 1 Mz
G (female) (1) and grounding value
4
defective
Between (35) and (25) 1.4 k – 3.5 kz
Circuit diagram related to engine G speed sensor
PC750, 800-7 20-381

(2)
Error Code in Electrical System E920 (Engine type selection error)
User Code Error Code Failure Code Failure Engine type selection error
E11 E920 DB29KQ phenomenon (Engine controller system)
• The model selection signal directly taken by the engine controller does not conform to the model in the
Failure content
controller or it is not confirmed.
• Control is carried out with the default model (PC750).
Response from
controller
• The model name (figure) recognized by the controller can be checked in the monitoring function.
Relative (Code No. 00201: Controller model code)
information • Input of the model selection signal (ON or OFF) can be checked in the monitoring function.
(Code No. 17400: Engine controller input state)

Model selection position during the troubleshooting.
connector defective E09 (female) Resistance value
1
short-circuiting) Between (1), (3) and (8) Above 1 Mz
Between (2) and (8) Below 1 z
harness
Wiring harness between E11 (female) (23) and E09 Resistance
Presumed cause and

(male) (2) value
tor) Wiring harness between E12 (female) (1) and E09 Resistance
Below 1 z
(male) (8) value
3 Above 1 Mz
(Contact with grounding E09 (male) (1) and grounding value
Above 1 Mz
E09 (male) (3) and grounding value
Engine controller E11, E12 Voltage
4
defective
Between E11 (3), (17) and E12 (1) 20 – 30 V
Between E11 (23) and E12 (1) Below 1 V
20-382 PC750, 800-7

(1)
Circuit diagram related to model selection connector (for engine controller)
PC750, 800-7 20-383

(1)
Error Code in Electrical System E921 (Engine type mismatch)
User Code Error Code Failure Code Failure Engine type mismatch
E11 E921 DB20KQ phenomenon (Engine controller system)
• The model information taken by the engine controller through the model selection connector does not
Failure content
conform to the model information taken from the pump controller by communication.
• The normal operation is continued.
Response from
controller
• The model name (figure) recognized by the engine controller can be checked in the monitoring func-
Relative tion. (Code No. 00201: Controller model code)
information • The model name (figure) recognized by the pump controller can be checked in the monitoring function.
(Code No. 00200: Controller model code)

Presumed cause and
Model selection connec-

1 If error code [E920] is displayed, carry out troubleshooting for it.
tor system defective
Engine controller Engine controller may be defective. (Since trouble is in the controller, troubleshoot-
2
defective ing cannot be carried out.)
Pump controller may be defective. (Since trouble is in the controller, troubleshooting

cannot be carried out.)
20-384 PC750, 800-7

(1)
Error Code in Electrical System E931 (Fuel dial sys. error)
User Code Error Code Failure Code Failure Fuel dial sys. error
E14 E931 DK10KX phenomenon (Engine controller system)
Failure content • The signal voltage from the fuel control dial is below 0.3 V or above 4.5 V.
• If the abnormality is detected before the engine is started, the fuel control dial signal is kept at 0% or
100% after the engine is started.
Response from
• If the abnormality is detected while the engine is running, the fuel control dial signal just before the
controller
abnormality is detected is kept.
Phenomenon
occurring on • The engine speed cannot be controlled.
machine
Relative • Input from the fuel control dial (voltage) can be checked in the monitoring function.
information (Code No. 03000: Fuel control dial voltage)

Fuel control dial defective E06 (male) Resistance value
1 (Internal disconnection or
Between (1) and (3) 4.0 – 6.0 kz
short-circuiting)
Between (1) and (2) 0.25 – 7.0 kz
Between (3) and (2) 0.25 – 7.0 kz
Disconnection of wiring Wiring harness between E12 (female) (19) and E06 Resistance
harness Below 1 z
(female) (1) value
tive contact with connec- Wiring harness between E12 (female) (10) and E06 Resistance
Below 1 z
tor) (female) (2) value

Presumed cause and
Wiring harness between E12 (female) (29), J09, and Resistance

Below 1 z
E06 (female) (3) value
3 Above 1 Mz
(Contact with grounding E06 (female) (1) and grounding value
Above 1 Mz
E06 (female) (2) and grounding value
Between wiring harness between E12 (female) (19) and
E06 (female) (1) and grounding
Voltage Below 1 V
E06 (female) (2) and grounding
Engine controller E12 Voltage
5
defective
Between (19) and (29) 4.6 – 5.4 V
Between (10) and (29) 0.3 – 4.5 V
20-386 PC750, 800-7

(1)
Circuit diagram related to fuel control dial
PC750, 800-7 20-387

(1)
Error Code in Electrical System E934 (Engine coolant sensor Hi error)
User Code Error Code Failure Code Failure Engine coolant sensor Hi error
E15 E934 DGE2KX phenomenon (Engine controller system)
Failure content • The signal voltage from the engine water high temperature sensor is below 0.5 V or above 4.5 V.
Response from • The signal of the engine water high temperature sensor is kept at 90°C.
Phenomenon • The engine does not start easily when temperature is low.
occurring on • The overheat protection function does not operate.
machine • If the controller is also defective, the engine does not stop.
• Input from the engine water high temperature sensor (voltage and water temperature) can be checked
Relative in the monitoring function.
information (Code No. 04106: Engine water temperature sensor Hi, 04102: Engine water temperature (High tem-
perature))

Engine water high tem- position during the troubleshooting.
perature sensor defective TWH (male) Resistance value
1
short circuit) Between (1) and (2) 3.5 k – 90 kz

Presumed cause and
harness
Wiring harness between E12 (female) (27) and TWH Resistance
(female) (1) value
tor) Wiring harness between E12 (female) (39), J09, and Resistance
Below 1 z
TWH (female) (2) value
3
(Contact with grounding Between wiring harness between E12 (female) (27) and Resistance
circuit) Above 1 Mz
TWH (female) (1) and grounding value
Engine controller E12 Resistance value
4
defective
Between (27) and (39) 3.5 k – 90 kz
20-388 PC750, 800-7

(1)
Circuit diagram related to engine water temperature sensor (for low temperature and high temperature)
PC750, 800-7 20-389

(1)
Error Code in Electrical System E936 (Engine oil press. sw. error)
User Code Error Code Failure Code Failure Engine oil press. sw. error
E15 E936 DDE2L6 phenomenon (Engine controller system)
• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of
the high-pressure switch is opened (disconnected from grounding) while the engine is running.
• The signal circuit of the low-pressure switch is opened (disconnected from grounding) while the engine
Failure content
is stopped (the starting signal is OFF).
• The signal circuit of the high-pressure switch is opened (disconnected from grounding) while the
engine is stopped (the starting signal is OFF).
Response from • None in particular.
Relative • Input from the engine oil pressure switch (Lo or Hi) (ON or OFF) can be checked in the monitoring func-
information tion. (Code No. 17400: Engine controller input)

Engine low-oil pressure position and start the engine during the troubleshooting.
switch defective PSL Engine Resistance value
1
short-circuiting) Between terminal Stopped Below 1 z
and grounding Low idling Above 1 Mz
position and start the engine during the troubleshooting.
Engine high-oil pressure
switch defective PSH Engine Resistance value
2
(Internal disconnection or Stopped Below 1 z
short-circuiting) Between terminal
and grounding Running at 1,300 rpm
Above 1 Mz
or higher

harness
Presumed cause and
Resistance
3 (Disconnection or defec- Wiring harness between E11 (female) (21) and PSL Below 1 z
value
tor) Resistance
Wiring harness between E11 (female) (15) and PSH Below 1 z
value
4 Above 1 Mz
(Contact with grounding PSL and grounding value
Above 1 Mz
PSH and grounding value
position and start the engine during the troubleshooting.
E11 Engine Voltage
Between (21) and ground- Stopped Below 1 V
ing (Low-pressure switch
Engine controller signal) Low idling 20 – 30 V
5
defective
Between (15) and ground- Stopped Below 1 V
ing (High-pressure switch Running at 1,300 rpm
signal) 20 – 30 V
or higher
Carry out troubleshooting while the engine is running 15 seconds after the engine is
started.
20-390 PC750, 800-7

(1)
Circuit diagram related to engine water temperature sensor (for low pressure and high pressure)
PC750, 800-7 20-391

(1)
Error Code in Electrical System E93C (Engine boost sensor error)
User Code Error Code Failure Code Failure Engine boost sensor error
E11 E93C DH30KX phenomenon (Engine controller system)
Failure content • The signal voltage from the boost pressure sensor is below 0.3 V or above 4.7 V.
• Input from the boost pressure sensor (voltage and pressure) can be checked in the monitoring function.
Relative
(Code No. 36501: Boost pressure sensor voltage, 36500: Boost pressure)
information
• Special adapter (799-601-9420) is necessary for troubleshooting for the engine boost pressure sensor.

PIM Voltage
Boost pressure sensor
Between (3) and (1) Power supply 4.6 – 5.4 V
1 defective
(Internal defect) Between (2) and (1) Signal 0.5 – 4.5 V
Disconnection of wiring Wiring harness between E12 (female) (9), J20, and PIM Resistance
harness Below 1 z
(female) (3) value
tive contact with connec- Wiring harness between E12 (female) (39), J09, and Resistance
Below 1 z
Presumed cause and
tor) PIM (female) (1) value

Wiring harness between E12 (female) (20) and PIM Resistance
Below 1 z
(female) (2) value
harness Between wiring harness between E12 (female) (9), J20, Resistance
3 Above 1 Mz
(Contact with grounding and PIM (female) (3) and grounding value
Above 1 Mz
PIM (female) (2) and grounding value
Between wiring harness between E12 (female) (9), J20,
and PIM (female) (3) and grounding
Voltage Below 1 V
PIM (female) (2) and grounding
5
defective
Between (9) and (39) 4.6 – 5.4 V
Between (20) and (39) 0.5 – 4.5 V
20-392 PC750, 800-7

(1)
Circuit diagram related to boost pressure sensor
PC750, 800-7 20-393

(1)
TROUBLESHOOTING E93D
Error Code in Electrical System E93D (Engine fuel temp. sensor error)
User Code Error Code Failure Code Failure Engine fuel temp. sensor error
E15 E93D DGE4KX phenomenon (Engine controller system)
Failure content • The signal voltage from the fuel temperature sensor is above 4.5 V.
Relative • Input from the fuel temperature sensor (voltage) can be checked in the monitoring function.
information (Code No. 14201: Fuel temperature sensor voltage)

Fuel temperature sensor position during the troubleshooting.
defective THL (male) Resistance value
1
short-circuiting) Between (A) and (B) 0.3 k – 9 kz
Between (A), (B) and grounding Above 1 Mz

Presumed cause and
harness
Wiring harness between E12 (female) (17) and THL Resistance
(female) (A) value
tor) Wiring harness between E12 (female) (29) and THL Resistance
Below 1 z
(female) (B) value
3
circuit) Above 1 Mz
THL (female) (A) and grounding value
4
defective
Between (17) and (29) 0.3 k – 9 kz
20-394 PC750, 800-7

(1)
TROUBLESHOOTING E93D
Circuit diagram related to fuel temperature sensor
PC750, 800-7 20-395

(1)
Error Code in Electrical System E953 (Engine Comm. Abnormality)
User Code Error Code Failure Code Failure Engine Comm. Abnormality
E0E E953 DB2RMC phenomenon (Engine controller system)
• The engine controller detected communication failure in the CAN communication circuit to the monitor
Failure content
panel or pump controller.
Phenomenon
occurring on
machine
Relative
information

harness Resistance
(female) (22)
Resistance
value
(female) (32)
Above 1 Mz
2

Presumed cause and

Above 1 Mz
3 harness
Voltage Below 1 V
4
defective K30 (male), K31 (male) Resistance value
Between (1) and (2) 40 – 80 z
Monitor panel, If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller
5 engine controller, or may be defective. (Since trouble is in those devices, troubleshooting cannot be car-
pump controller defective ried out.)
20-396 PC750, 800-7

(1)
PC750, 800-7 20-397

(1)
Error Code in Electrical System E954 (Short engine starter sw.)
User Code Error Code Failure Code Failure Short engine starter sw.
— E954 DD11KB phenomenon (Engine controller system)
Failure content • Starting switch signal C (starting signal) is detected while the engine is running (at 500 rpm or higher).
Response from • Starting switch signal is recognized to be OFF.
Phenomenon
occurring on • The machine operates normally.
machine
Relative • Input of starting switch signal C (ON or OFF) can be checked in the monitoring function.
information (Code No. 17400: Engine controller input)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF and
ON positions during the troubleshooting.
Starting switch defective Starting switch Resistance value
1
Between terminal B OFF Above 1 Mz
and terminal C START Below 1 z
Presumed cause and

Between wiring harness between starting switch termi-
Short-circuiting of wiring nal C, J01, and E11 (female) (20) or between starting
2 harness switch terminal C and C01 (female) (17) or between
(Contact with 24 V circuit) starting switch terminal C and P01 (female) (4) or Voltage Below 1 V
between starting switch terminal C and R11 (female) (5),
or between starting switch terminal C and related cir-
cuits and grounding
Engine controller
4 E11 Starting switch Voltage
defective
Between (20) and ON
Below 1 V
grounding (Engine is running)
20-398 PC750, 800-7

(1)
Circuit diagram related to preheating, starting and charging of engine
PC750, 800-7 20-399

(1)
Error Code in Electrical System E955 (Engine S-NET error)
User Code Error Code Failure Code Failure Engine S-NET error
E0E E955 DB2SMC phenomenon (Engine controller system)
• The engine controller detected communication failure in the S-NET communication circuit to the moni-
Failure content
tor panel or pump controller.
Phenomenon
occurring on
machine

tor) value
2
circuit) Above 1 Mz
(9), (10) and C02 (female) (21) or between P02 (female) value
Presumed cause and

(9), (10) and C02 (female) (21) or between P02 (female)
P02 Voltage
Between (9), (10) and (20) 6–9V
5
Between (21), (31) and (11) 6–9V
C02 Voltage
20-400 PC750, 800-7

(1)
PC750, 800-7 20-401

(1)
Error Code in Electrical System E956 (Engine power failure (1))
User Code Error Code Failure Code Failure Engine power failure (1)
E10 E956 DB22KK phenomenon (Engine controller system)
Failure content • When the starting switch is turned ON, the source voltage of the controller is below 10 V.
Phenomenon
• The engine stalls.
occurring on
• The engine cannot be started.
machine
Relative
information

Circuit breaker 7 If circuit breaker is turned OFF, the circuit probably has grounding fault, etc.
1
defective (See cause 4.)
Engine controller power a Turn the engine starting switch OFF for the preparations, and hold it in the ON
supply relay defective position during the troubleshooting.
2
(Internal disconnection or Replace the power supply relay with another one. If the condition
short-circuiting) R22
becomes normal, the relay is defective.
Wiring harness between E13 (female) (1), (2), (21) and Resistance
Below 1 z
R22 (female) (5) value
Disconnection of wiring Resistance
harness Wiring harness between R22 (female) (3) and B27 Below 1 z
value
Wiring harness between B17 and battery relay B termi- Resistance
Presumed cause and
tive contact with connec- Below 1 z

tor) nal value
Wiring harness between R22 (female) (1) and J02 Resistance
Below 1 z
(male) (1) value
Resistance
Wiring harness between R22 (female) (2) and grounding Below 1 z
value
Between wiring harness between E13 (female) (1), (2), Resistance
Grounding fault of wiring Above 1 Mz
(21) and R22 (female) (5) and grounding value
harness
4 Between wiring harness between R22 (female) (3) and Resistance
(Contact with grounding Above 1 Mz
circuit) B27 value
Between wiring harness between R22 (female) (1) and
Resistance
J02 (male) (1) or between R22 (female) (1) and related Above 1 Mz
value
circuits and grounding
Engine controller E13 Starting switch Voltage
5
defective
Between (1), (2), (21) OFF Below 1 V
and (11), (31), (32) ON 20 – 30 V
20-402 PC750, 800-7

(1)
Circuit diagram related to engine controller power supply
PC750, 800-7 20-403

(1)
Error Code in Electrical System E957 (Engine power failure (2))
User Code Error Code Failure Code Failure Engine power failure (2)
E15 E957 D1D0KB phenomenon (Engine controller system)
Failure content • When the starting switch is turned OFF, the source voltage of the controller is above 10 V.
Relative
information

Engine controller power position during the troubleshooting.
1 supply relay defective
(Internal short-circuiting) Replace the power supply relay with another one. If the condition
R22
becomes normal, the relay is defective.
Presumed cause and

Short-circuiting of wiring Between wiring harness between E13 (female) (1), (2),
Voltage Below 1 V
2 harness (21) and R22 (female) (5) and grounding
(Contact with 24 V circuit) Between wiring harness between R22 (female) (1) and
J02 (male) (1) or between R22 (female) (1) and related Voltage Below 1 V
circuits and grounding
Engine controller E13 Starting switch Voltage
3
defective
Between (1), (2), (21) OFF Below 1 V
and (11), (31), (32) ON 20 – 30 V
20-404 PC750, 800-7

(1)
PC750, 800-7 20-405

(1)
TROUBLESHOOTING E95A
Error Code in Electrical System E95A (Engine Q-adj. sw. signal error)
User Code Error Code Failure Code Failure Engine Q-adj. sw. signal error
— E95A DB2AMA phenomenon (Engine controller system)
Failure content • The fuel injection amount adjustment switch of the controller is not set to the correct position.
Phenomenon
occurring on • Setting of the fuel injection amount adjustment switch cannot be changed.
machine
• Setting (Set position) of the fuel injection amount adjustment switch can be checked in the monitoring
Relative
function. (Code No. 36800: Right fuel injection amount adjustment switch, 36801: Left fuel injection
information
amount adjustment switch)

Presumed cause and
Setting of fuel injection

amount adjustment If the fuel injection amount adjustment switch 1 (right) or 2 (left) is set in [F], its setting
1
switch of engine is wrong.
controller defective
Engine controller
2 If the cause is not detected, engine controller may be defective.
defective
20-406 PC750, 800-7

(1)
Error Code in Electrical System E96A (Engine coolant sensor Lo error)
User Code Error Code Failure Code Failure Engine coolant sensor Lo error
E15 E96A DGE3L6 phenomenon (Engine controller system)
Failure content • The signal voltage from the engine water low temperature sensor is above 4.5 V.
• The signal of the engine water low temperature sensor is kept at 20°C (If the signal of the high temper-
Response from
ature sensor is effective, it is used as a substitute).
controller
• Input from the engine water low temperature sensor (voltage and water temperature) can be checked
Relative
in the monitoring function. (Code No. 04105: Engine water temperature sensor voltage Lo, 04107:
information
Engine water temperature (Low temperature))

Engine water low
temperature sensor
1 defective TWL (male) Resistance value
(Internal disconnection or Between (A) and (B) 0.3 k – 9 kz
short circuiting)
Between (A), (B) and grounding Above 1 Mz

Presumed cause and
harness
Wiring harness between E12 (female) (37) and TWL Resistance
(female) (A) value
tor) Wiring harness between E12 (female) (39), J09, and Resistance
Below 1 z
TWL (female) (B) value
3
circuit) Above 1 Mz
TWL (female) (A) and grounding value
4
defective
Between (37) and (39) 0.3 k – 9 kz
20-408 PC750, 800-7

(1)
PC750, 800-7 20-409

(1)
Error Code in Electrical System E970 (PCV1 over current)
User Code Error Code Failure Code Failure PCV1 over current
E11 E970 AD11KB phenomenon (Engine controller system)
Failure content • Abnormal current flowed in the fuel supply pump PCV1 circuit.
• Power to the fuel supply pump PCV1 circuit is switched OFF.
Response from
controller
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idling.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.
information

Fuel supply pump PCV1 position during the troubleshooting.
defective PCV1 (male) Resistance value
1
(Internal short circuiting
or grounding fault) Between (1) and (2) 2.3 – 5.3 z
Grounding fault of wiring

Presumed cause and
2
circuit) Above 1 Mz
PCV1 (female) (1) value
PCV1 (female) (1)
Voltage Below 1 V
PCV1 (female) (2)
4
defective
Between (12) and (22) 2.3 – 5.3 z
20-410 PC750, 800-7

(1)
Circuit diagram related to fuel supply pump PCV1
PC750, 800-7 20-411

(1)
Error Code in Electrical System E971 (PCV2 over current)
User Code Error Code Failure Code Failure PCV2 over current
E11 E971 AD51KB phenomenon (Engine controller system)
Failure content • Abnormal current flowed in the fuel supply pump PCV2 circuit.
Response from
controller
Phenomenon
occurring on
machine
Relative
information

Fuel supply pump PCV2 position during the troubleshooting.
defective PCV2 (male) Resistance value
1
(Internal short circuiting

Presumed cause and
2
circuit) Above 1 Mz
PCV2 (female) (1)
Voltage Below 1 V
PCV2 (female) (2)
4
defective
Between (13) and (23) 2.3 – 5.3 z
20-412 PC750, 800-7

(1)
PC750, 800-7 20-413

(1)
Error Code in Electrical System E974 (PCV1 line cut)
User Code Error Code Failure Code Failure PCV1 line cut
E11 E974 AD11KA phenomenon (Engine controller system)
Failure content • Fuel supply pump PCV1 circuit is disconnected.
Response from
controller
Phenomenon
occurring on
machine
Relative
information

Fuel supply pump PCV1
1 defective PCV1 (male) Resistance value
(Internal short circuiting) Between (1) and (2) 2.3 – 5.3 z

Presumed cause and
harness
Between wiring harness between E13 (female) (12) and Resistance
tor) Between wiring harness between E13 (female) (22) and Resistance
Below 1 z
3
circuit) Above 1 Mz
4
defective
Between (12) and (22) 2.3 – 5.3 z
20-414 PC750, 800-7

(1)
PC750, 800-7 20-415

(1)
Error Code in Electrical System E975 (PCV2 line cut)
User Code Error Code Failure Code Failure PCV2 line cut
E11 E975 AD51KA phenomenon (Engine controller system)
Failure content • Fuel supply pump PCV2 circuit is disconnected.
Response from
controller
Phenomenon
occurring on
machine
Relative
information

Fuel supply pump PCV2
1 defective PCV2 (male) Resistance value
(Internal short circuiting) Between (1) and (2) 2.3 – 5.3 z

Presumed cause and
harness
tor) Between wiring harness between E13 (female) (23) and Resistance
Below 1 z
3
circuit) Above 1 Mz
4
defective
Between (13) and (23) 2.3 – 5.3 z
20-416 PC750, 800-7

(1)
PC750, 800-7 20-417

(1)
Error Code in Electrical System E977 (Rail press. sensor error)
User Code Error Code Failure Code Failure Rail press. sensor error
E11 E977 DH40KX phenomenon (Engine controller system)
Failure content • The signal voltage from the common rail fuel pressure sensor is below 0.7 V or above 4.5 V.
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
Relative
function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
information
• Special adapter (799-601-9420) is necessary for troubleshooting for common rail fuel pressure sensor.

Common rail fuel PFUEL Voltage

pressure sensor Between (3) and (1) Power supply 4.6 – 5.4 V
1
defective Between (2) and (1) Signal 0.7 – 4.5 V
(Internal defect)
Disconnection of wiring Wiring harness between E12 (female) (9), J20, and Resistance
harness Below 1 z
PFUEL (female) (3) value
tive contact with connec- Wiring harness between E12 (female) (39), J09, and Resistance
Below 1 z
Presumed cause and
tor) PFUEL (female) (1) value

Wiring harness between E12 (female) (40) and PFUEL Resistance
Below 1 z
(female) (2) value
harness Between wiring harness between E12 (female) (9), J20, Resistance
3 Above 1 Mz
(Contact with grounding and PFUEL (female) (3) and grounding value
Above 1 Mz
PFUEL (female) (2) and grounding value
Between wiring harness between E12 (female) (9), J20,
and PFUEL (female) (3) and grounding
Voltage Below 1 V
PFUEL (female) (2) and grounding
5
defective
Between (9) and (39) 4.6 – 5.4 V
Between (40) and (39) 0.7 – 4.5 V
20-418 PC750, 800-7

(1)
Circuit diagram related to common rail fuel pressure sensor
PC750, 800-7 20-419

(1)
Error Code in Electrical System E979 (Rail press. high)
User Code Error Code Failure Code Failure Rail press. high
E11 E979 AD00L2 phenomenon (Engine controller system)
Failure content • The signal circuit of the common rail fuel pressure sensor detected high pressure (level 1).
Relative • Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
information function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)

Related systems If any other error code or failure code is displayed, carry out troubleshooting for it
1
defective first.
2 Fuel used improper Fuel used may be improper. Check it directly.

Presumed cause and
Electric system of
3 common rail fuel Carry out troubleshooting for error code [E977].
pressure sensor defective
Mechanical system of
The common rail fuel pressure sensor may have a mechanical defect. Check it
4 common rail fuel
directly.
pressure sensor defective
The overflow valve may have trouble of breakage of spring, wear of seat, or fixing of
5 Overflow valve defective
ball. Check it directly.
6 Overflow piping clogged The overflow piping may be clogged. Check it directly.
7 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.
Error Code in Electrical System E97A (Rail press. abnormal)
User Code Error Code Failure Code Failure Rail press. abnormal
E11 E97A AD00MA phenomenon (Engine controller system)
Failure content • The signal circuit of the common rail fuel pressure sensor detected high pressure (level 2).
Response from
controller
Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Common rail-related
1 Carry out troubleshooting for error code [E979].
in normalcy device defective
20-420 PC750, 800-7

(1)
Error Code in Electrical System E97B (Rail press. low)
User Code Error Code Failure Code Failure Rail press. low
E15 E97B AD10L3 phenomenon (Engine controller system)
Failure content • No-pressure feed by fuel supply pump (level 1) occurred.
Response from
controller

Related systems If any other error code or failure code is displayed, carry out troubleshooting for it
1
defective first.
2 Fuel used improper Fuel used may be improper. Check it directly.
Fuel low-pressure circuit A low-pressure circuit device may be defective. Referring to Note 1, carry out trou-
3
device defective bleshooting.

Presumed cause and
Fuel filter/strainer The fuel filter/strainer may be clogged. Referring to Note 2, carry out troubleshoot-
4
clogged ing.
Electrical system of fuel
5 supply pump PCV1 Carry out troubleshooting for error codes [E970], [E971], [E974], and [E975].
defective
Fuel supply pump
6 The fuel supply pump may be defective. Check it directly.
defective
Common rail fuel
7 pressure sensor The common rail fuel pressure sensor may be defective. Check it directly.
defective
8 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.
9 Fuel injector defective The fuel injector may be defective. Referring to Note 3, check it directly.
NOTE 1: Check the low-pressure circuit devices for the following points.
1) Insufficiency of fuel
2) Fixing and wear of feed pump and clogging of filter
3) Leakage from and clogging of low-pressure fuel piping
4) Malfunction of bypass valve and installation of wrong part (See Fig. 1)
5) Clogging of fuel filter
6) Entry of fuel in oil pan (Fuel leakage in head cover)
• Fuel low-pressure circuit pressure: 0.15 – 0.3 MPa {1.5 – 3.0 kg/cm2}
PC750, 800-7 20-421

(1)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
• Overflow valve (1): Spring is seen through both holes.
• Bypass valve (2): Spring is seen through hole on nut side.
• Fuel inlet joint (3): Gauze filter is seen through both holes.
NOTE 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check the gauze filter. If it is clogged, clean it.
2) Strainer on upstream side of gauze filter: If the gauze filter is clogged, clean the upstream strainer too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
NOTE 3: Judge the condition of the fuel injector by 3) Run the engine and stall at each speed
k When performing the follow work, take care

measuring the fuel spill rate. (relieve the arm circuit by moving the arm
in). Measure the quantity of the fuel spilling
not to scald yourself with the fuel which be- in 1 minute under this condition.
comes hot (up to 90°C). a Limit of spill of fuel (Total of spill from 6
1) Disconnect the hose connected to the cen- cylinders)
tralized return spill tube adapters (at the rear
Stall speed (rpm) Limit of spill (cc/min)
of the engine).
2) Connect another hose to the spill tube end 1,600 960
so that spill fuel can be received in a con- 1,700 1,020
tainer.
1,800 1,080
1,900 1,140
2,000 1,200
20-422 PC750, 800-7

(1)
TROUBLESHOOTING E97C, E97D
Error Code in Electrical System E97C (Rail press. too low)
User Code Error Code Failure Code Failure Rail press. too low
E11 E97C AD10MB phenomenon (Engine controller system)
Failure content • No-pressure feed by fuel supply pump (level 2) occurred.
• The machine is driven with limited output and speed.
Response from
controller

cause and
1 Carry out troubleshooting for error code [E97B].
Error Code in Electrical System E97D (Rail press. out of control)
User Code Error Code Failure Code Failure Rail press. out of control
E11 E97D AD10MA phenomenon (Engine controller system)
Failure content • Abnormal fuel pressure was generated in the common rail.
• The machine is driven under the normal control.
Response from
controller

cause and
1 Carry out troubleshooting for error code [E97B].
PC750, 800-7 20-423

(1)
Error Code in Electrical System E980 (Eng. Controller Abnormality)
User Code Error Code Failure Code Failure Eng. Controller Abnormality
E10 or E11 E980 DB20KT phenomenon (Engine controller system)
Failure content • The controller has abnormality in it.
• The machine is driven with limited output or all output is turned OFF.
Response from
controller
Phenomenon
occurring on
machine
• The engine stop and it cannot be started (when user code [E10] is displayed).
Relative
information

Presumed cause and
tive contact with connec- Wiring harness between E13 (female) (11), (31), (32) Resistance
Below 1 z
tor) and grounding value
Engine controller If cause 1 is not detected, the engine controller may be defective.
2
defective (Since trouble is in the engine controller, troubleshooting cannot be carried out.)
20-424 PC750, 800-7

(1)
PC750, 800-7 20-425

(1)
Error Code in Electrical System E981 (Fuel Injector 1 Disc.)
User Code Error Code Failure Code Failure Fuel Injector 1 Disc.
E11 E981 ADA1KA phenomenon (Engine controller system)
Failure content • Fuel injector 1 circuit is disconnected.
• Power to the fuel injector 1 circuit is switched OFF.
Response from
controller
Phenomenon
occurring on
machine
Relative
information

Fuel injector 1 defective position during the troubleshooting.
1
(Internal disconnection) CN1 (male) Resistance value
Between (1) and (2) 0.4 – 1.1 z

Presumed cause and
harness
Wiring harness between E13 (female) (14) and CN1 Resistance
(female) (1) value
tor) Wiring harness between E13 (female) (24) and CN1 Resistance
Below 1 z
(female) (2) value
3
defective E13 (female) Resistance value
Between (14) and (24) 0.4 – 1.1 z
Circuit diagram related to fuel injector 1
20-426 PC750, 800-7

(1)
E11 E982 ADB1KA phenomenon (Engine controller system)
Response from
controller
Phenomenon
occurring on
machine
Relative
information

1
Between (1) and (2) 0.4 – 1.1 z

Presumed cause and
harness
(female) (1) value
Below 1 z
(female) (2) value
3
Between (6) and (16) 0.4 – 1.1 z
PC750, 800-7 20-427

(1)
E11 E983 ADC1KA phenomenon (Engine controller system)
Response from
controller
Phenomenon
occurring on
machine
Relative
information

1
Between (1) and (2) 0.4 – 1.1 z

Presumed cause and
harness
(female) (1) value
Below 1 z
(female) (2) value
3
Between (5) and (15) 0.4 – 1.1 z
20-428 PC750, 800-7

(1)
E11 E984 ADD1KA phenomenon (Engine controller system)
Response from
controller
Phenomenon
occurring on
machine
Relative
information

1
Between (1) and (2) 0.4 – 1.1 z

Presumed cause and
harness
(female) (1) value
Below 1 z
(female) (2) value
3
Between (26) and (36) 0.4 – 1.1 z
PC750, 800-7 20-429

(1)
E11 E985 ADF1KA phenomenon (Engine controller system)
Response from
controller
Phenomenon
occurring on
machine
Relative
information

1
Between (1) and (2) 0.4 – 1.1 z

Presumed cause and
harness
(female) (1) value
Below 1 z
(female) (2) value
3
Between (34) and (33) 0.4 – 1.1 z
20-430 PC750, 800-7

(1)
E11 E986 ADF1KA phenomenon (Engine controller system)
Response from
controller
Phenomenon
occurring on
machine
Relative
information

1
Between (1) and (2) 0.4 – 1.1 z

Presumed cause and
harness
(female) (1) value
Below 1 z
(female) (2) value
3
Between (25) and (35) 0.4 – 1.1 z
PC750, 800-7 20-431

(1)
Error Code in Electrical System E98A (Fuel Injector 1 – 3 S/C)
User Code Error Code Failure Code Failure Fuel Injector 1 – 3 S/C
E11 E98A ADAZKB phenomenon (Engine controller system)
Failure content • Abnormal current flowed in the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit.
• Power to the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit is switched OFF.
Response from
controller
Phenomenon
occurring on
machine
Relative
information

Fuel injector 1 defective
1 (Internal short-circuiting CN1 (male) Resistance value
Presumed cause and

Above 1 Mz
CN1 (female) (1) and grounding value
Above 1 Mz
Grounding fault of wiring CN1 (female) (2) and grounding value
4 Above 1 Mz
(Contact with grounding CN2 (female) (1) and grounding value
Above 1 Mz
Above 1 Mz
Above 1 Mz
20-432 PC750, 800-7

(1)

Voltage Below 1 V
CN1 (female) (1) and grounding
Voltage Below 1 V

Presumed cause and

Voltage Below 1 V
Voltage Below 1 V
Voltage Below 1 V
E13 (female) Resistance value
Engine controller Between (14) and (24) 0.4 – 1.1 z
6
defective Between (6) and (16) 0.4 – 1.1 z
Between (5) and (15) 0.4 – 1.1 z
Between (5), (6), (14), (15), (16), (24)
Above 1 Mz
and grounding
Circuit diagram related to fuel injectors 1, 2, and 3
PC750, 800-7 20-433

(1)
Error Code in Electrical System E98B (Fuel Injector 4 – 6 S/C)
User Code Error Code Failure Code Failure Fuel Injector 4 – 6 S/C
E11 E98B ADDZKB phenomenon (Engine controller system)
Failure content • Abnormal current flowed in the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit.
• Power to the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit is switched OFF.
Response from
controller
Phenomenon
occurring on
machine
Relative
information

Presumed cause and

Above 1 Mz
Above 1 Mz
Grounding fault of wiring CN4 (female) (2) and grounding value
4 Above 1 Mz
(Contact with grounding CN5 (female) (1) and grounding value
Above 1 Mz
Above 1 Mz
Above 1 Mz
20-434 PC750, 800-7

(1)

Voltage Below 1 V
Voltage Below 1 V

Presumed cause and

Voltage Below 1 V
Voltage Below 1 V
Voltage Below 1 V
E13 (female) Resistance value
Engine controller Between (26) and (36) 0.4 – 1.1 z
6
defective Between (34) and (33) 0.4 – 1.1 z
Between (25) and (35) 0.4 – 1.1 z
Between (25), (26), (33), (34), (35), (36)
Above 1 Mz
and grounding
Circuit diagram related to fuel injectors 4, 5, and 6
PC750, 800-7 20-435

(1)
TROUBLESHOOTING A000N1
Failure Code in Mechanical System A000N1 (Eng. Hi Out of Std)
User Code Error Code Failure Code Failure Eng. Hi Out of Std
— — A000N1 phenomenon (Mechanical system)
Failure content • Engine speed higher than 2,500 rpm is detected while the engine is running.
Response from
• None in particular.
controller
Phenomenon
occurring on • If the machine is used as it is, the engine may be damaged.
machine
Relative • Input from the engine speed sensor (rpm) can be checked in the monitoring function.
information (Code No. 01002: Engine speed)

Engine overrun Check for external and internal causes for abnormal rise of the engine high idling
1
(While system is normal) speed, then carry out troubleshooting for the mechanical system of the engine.
Presumed cause and
Engine Ne sensor system

2 If error code [E91B] is displayed, carry out troubleshooting for it.
defective
Engine G sensor system
3 If error code [E91C] is displayed, carry out troubleshooting for it.
defective
a Turn the engine starting switch ON for the preparations, and keep the engine
Engine controller
4 Monitoring Engine Engine speed
defective
010006
High idling 1,930 – 2,030 rpm
Engine speed
PC750, 800-7 20-437

(1)
TROUBLESHOOTING AA10NX
Failure Code in Mechanical System AA10NX (Aircleaner Clogging)
User Code Error Code Failure Code Failure Aircleaner Clogging

— — AA10NX phenomenon (Mechanical system)
• The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine
Failure content
is running.
Response from
controller
Phenomenon
machine
• If the air cleaner clogging monitor on the monitor panel lights up in red while the engine is running, this
Relative failure code is recorded.
information • Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function.
(Code No. 04501: Monitor input 1)

Air cleaner clogged
1 Check the air cleaner. If it is clogged, clean or replace it.
(While system is normal)
position or keep the engine running during the troubleshooting.
Air cleaner clogging
2 switch defective P11 (male) Air cleaner Resistance value
(Internal disconnection) Normal Below 1 z

Presumed cause and
Between (1) and (2)

Clogged Above 1 Mz
harness
Wiring harness between P02 (female) (5) and P11 Resistance
(female) (1) value
tor) Wiring harness between P11 (female) (2), J21, and Resistance
Below 1 z
grounding value
position or keep the engine running during the troubleshooting.
4 Monitor panel defective P02 Air cleaner Voltage
Normal Below 1 V
Clogged 20 – 30 V
20-438 PC750, 800-7

(1)
TROUBLESHOOTING AA10NX
Circuit diagram related to air cleaner clogging switch
PC750, 800-7 20-439

(1)
TROUBLESHOOTING AB00KE
Failure Code in Mechanical System AB00KE (Charge Voltage Low)
User Code Error Code Failure Code Failure Charge Voltage Low
— — AB00KE phenomenon (Mechanical system)
Failure content • Signal voltage from alternator is below 20 V while the engine is running.
Response from
controller
Phenomenon
occurring on • If the machine is used as it is, the battery may not be charged.
machine
• If the charge level monitor on the monitor panel lights up in red while the engine is running, this failure
Relative code is recorded.
information • Input from the alternator (Voltage, ON or OFF) can be checked in the monitoring function.
(Code No. 04300: Charge voltage, 04501: Monitor input 2)

Alternator defective Alternator Engine Voltage
1
(Internal defect) Between terminal R
Above low idling Above 20 V
and grounding
If the voltage is abnormal, check the belt tension too.

Presumed cause and
tive contact with connec- Wiring harness between P02 (female) (11), J02, and Resistance
Below 1 z
tor) alternator terminal R value
harness Between wiring harness between P02 (female) (11),
3 J02, and alternator terminal R, or between P02 (female)
circuit) (11), D01, J01, and starting switch terminal BR, or Above 1 Mz
value
between P02 (female) (11), battery relay terminal BR
and grounding
4 Monitor panel defective P02 Engine Voltage
Between (11) and
Above low idling Above 20 V
grounding
20-440 PC750, 800-7

(1)
TROUBLESHOOTING AB00KE
Circuit diagram related to engine preheating, starting, and charging circuits
PC750, 800-7 20-441

(1)
TROUBLESHOOTING B@BAZG
Failure Code in Mechanical System B@BAZG (Eng. Oil Press. Low)
User Code Error Code Failure Code Failure Eng. Oil Press. Low
E11 E924 B@BAZG phenomenon (Mechanical system)
• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of
the high-pressure switch is closed (connected to grounding) while the engine speed is above 600 rpm.
Failure content • The signal circuit of the low-pressure switch is opened (disconnected from grounding) and the signal
circuit of the high-pressure switch is closed (connected to grounding) while the engine speed is above
1,300 rpm.
Response from
controller
Phenomenon
machine
• When this failure occurs, the error code is displayed only when the user code is turned ON and the fail-
ure code is recorded in only the mechanical system of the failure history.
Relative • If the engine oil pressure monitor on the monitor panel lights up in red while the engine is running, this
information failure code is recorded.
• Input from the engine oil pressure switch (ON or OFF) can be checked in the monitoring function.
(Code No. 17400: Engine controller input)

Engine oil pressure
Check the engine oil pressure. If it is abnormal, find out the cause and check the
1 lowered
engine for damage, then repair.
(While system is normal)
Engine oil pressure

2 Carry out troubleshooting for error code [E936].
Presumed cause and
switch system defective

position or start the engine during the troubleshooting.
E11 Engine Voltage
Between (21) and grounding Stopped Below 1 V
Engine controller (Low-pressure switch signal)
3 Low idling 20 – 30 V
defective
Between (15) and grounding Stopped Below 1 V
(High-pressure switch signal) Above 1,300 rpm 20 – 30 V
When carrying out troubleshooting while the engine is running, wait for 15 seconds
after the engine is started.
20-442 PC750, 800-7

(1)
TROUBLESHOOTING B@BAZG
Circuit diagram related to engine oil pressure sensors (for low pressure and high pressure)
PC750, 800-7 20-443

(1)
TROUBLESHOOTING B@BAZK
Failure Code in Mechanical System B@BAZK (Eng. Oil Level Low)
User Code Error Code Failure Code Failure Eng. Oil Level Low
— — B@BAZK phenomenon (Mechanical system)
• The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the
Failure content
engine is stopped.
Response from
controller
Phenomenon
machine
• If the engine oil level monitor on the monitor panel lights up in red while the engine is running, this fail-
Relative ure code is recorded.
information • Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function.

Engine oil level low Check the oil level in the engine oil pan. If it is low, add oil. (If it is reduced fre-
1
(While system is normal) quently, find out the cause.)
Engine oil level switch
2 OL (male) Engine oil level Resistance value

defective
Presumed cause and
Normal level Below 1 z

Below normal level Above 1 Mz
tive contact with connec- Wiring harness between P02 (female) (8) and OL Resistance
Below 1 z
4 Monitor panel defective P02 Engine oil level Voltage
Normal level Below 1 V
Below normal level 20 – 30 V
Circuit diagram related to engine oil level switch
20-444 PC750, 800-7

(1)
TROUBLESHOOTING B@BCNS
Failure Code in Mechanical System B@BCNS (Eng. Water Overheat)
User Code Error Code Failure Code Failure Eng. Water Overheat
— — B@BCNS phenomenon (Mechanical system)
Failure content • The signal circuit of the engine water high temperature sensor detected temperature above 105°C.
Response from
controller
Phenomenon
machine
• If the engine water temperature monitor on the monitor panel lights up in red while the engine is run-
ning, this failure code is recorded.
Relative
• Input from the engine water high temperature sensor (water temperature and voltage) can be checked
information
in the monitoring function. (Code No. 04102: Engine water temperature (High), 04106: Engine water
temperature sensor voltage Hi)

Engine overheated Check the engine for overheating. If it has been overheated, find out the cause and
1
Presumed cause and
(While system is normal) check the engine for damage, then repair.
Engine water high
Carry out troubleshooting for "Display of engine water temperature gauge on monitor
2 temperature sensor
panel is abnormal" in E-mode.
system defective
3
defective E12 (female) Engine water temperature Resistance value
Between (27) and (39) 105°C 3.28 kz
PC750, 800-7 20-445

(1)
TROUBLESHOOTING B@BCZK
Failure Code in Mechanical System B@BCZK (Eng. Water Lvl Low)
User Code Error Code Failure Code Failure Eng. Water Lvl Low
— — B@BCZK phenomenon (Mechanical system)
• The signal circuit of the radiator water level switch is opened (disconnected from grounding) while the
Failure content
engine is running.
Response from
controller
Phenomenon
occurring on • If the machine is used as it is, the engine will overheat.
machine
• If the radiator water level monitor on the monitor panel lights up in red while the engine is stopped (the
Relative starting switch is at the ON position), this failure code is recorded.
information • Input from the radiator water level switch (ON or OFF) can be checked in the monitoring function.

Sub-tank water level low Check the radiator sub-tank water level. If it is low, add water. (If it is reduced fre-
1
(While system is normal) quently, find out the cause.)
Radiator water level
2 switch 1 defective P08 (male) Sub-tank water level Resistance value
(Internal disconnection) Within normal level Below 1 z
Between (1) and (2)
Below LOW level Above 1 Mz

Radiator water level
Presumed cause and
3 switch 2 defective P20 (male) Sub-tank water level Resistance value

(Internal disconnection) Within normal level Below 1 z
Between (1) and (2)
Below LOW level Above 1 Mz
Disconnection of wiring Wiring harness between P02 (female) (3) and P08 Resistance
harness Below 1 z
(female) (1) value
tive contact with connec- Wiring harness between P08 (female) (2) and P20 Resistance
Below 1 z
Resistance
Wiring harness between P20 (female) (2) and grounding Below 1 z
value
5 Monitor panel defective P02 Sub-tank water level Voltage
Within normal level Below 1 V
Below LOW level 20 – 30 V
20-446 PC750, 800-7

(1)
TROUBLESHOOTING B@BCZK
Circuit diagram related to radiator water level switch
PC750, 800-7 20-447

(1)
TROUBLESHOOTING B@HANS
Failure Code in Mechanical System B@HANS (Hydr. Oil Overheat)
User Code Error Code Failure Code Failure Hydr. Oil Overheat
— — B@HANS phenomenon (Mechanical system)
Failure content • The signal of the hydraulic oil temperature sensor rises above 102°C while the engine is running.
Response from
controller
Phenomenon
occurring on • If the machine is used as it is, the hydraulic equipment may be damaged.
machine
• If the hydraulic oil temperature monitor on the monitor panel lights up in red while the engine is running,
Relative this failure code is recorded.
information • Input from the hydraulic oil temperature sensor (temperature) can be checked in the monitoring func-
tion. (Code No. 04401: Hydraulic oil temperature)

Hydraulic oil overheated Check the hydraulic oil for overheating. If it has been overheated, find out the cause
1
(While system is normal) and check the hydraulic equipment for damage, then repair.
Hydraulic oil temperature
2 sensor defective P10 (male) Hydraulic oil temperature Resistance value

Presumed cause and
(Internal short-circuiting) Between (1) and (2) 90 – 3.5 kz

10 – 100°C
3
circuit) Above 1 Mz
P10 (female) (1) and grounding value
P02 Hydraulic oil temperature Resistance value
Between (12) and (13) 90 – 3.5 kz
Between (12) and 10 – 100°C
Above 1 Mz
grounding
20-448 PC750, 800-7

(1)
TROUBLESHOOTING B@HANS
Circuit diagram related to hydraulic oil temperature sensor
PC750, 800-7 20-449

(1)
TROUBLESHOOTING DA80MA
Failure Code in Mechanical System DA80MA (Auto. Lub Abnormal.)
a This failure code is applicable only when the auto grease device is installed.
20-450 PC750, 800-7

(1)
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E MODE)
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE).................................................................. 20-502

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-504
E-1 Engine does not start (Engine does not rotate) .................................................................................... 20-505
E-2 Preheater does not operate.................................................................................................................. 20-508
E-3 Auto engine warm-up device does not work ........................................................................................ 20-510
E-4 Auto-decelerator does not operate ....................................................................................................... 20- 511
E-5 All work equipment, swing and travel do not move .............................................................................. 20-512
E-6 Machine push-up function does not operate normally.......................................................................... 20-514
E-7 Boom shockless function does not operate normally ........................................................................... 20-516
E-8 Any item is not displayed on monitor panel .......................................................................................... 20-518
E-9 Part of display on monitor panel is missing .......................................................................................... 20-519
E-10 Monitor panel displays contents irrelevant to the model .................................................................... 20-519
E-11 Fuel level monitor red lamp lights up while engine is running ............................................................ 20-520
E-12 Engine water thermometer does not display normally ....................................................................... 20-522
E-13 Hydraulic oil temperature gauge does not display correctly ............................................................... 20-524
E-14 Fuel gauge does not display correctly ................................................................................................ 20-525
E-15 Swing lock monitor does not display correctly.................................................................................... 20-526
E-16 When monitor switch is operated, nothing is displayed...................................................................... 20-528
E-17 Windshield wiper and window washer do not work ............................................................................ 20-530
E-18 Alarming buzzer cannot be cancelled ................................................................................................ 20-538
E-19 "Boom RAISE" is not correctly displayed in monitor function ............................................................. 20-539
E-20 "Boom LOWER" is not correctly displayed in monitor function........................................................... 20-540
E-21 "Arm IN" is not correctly displayed in monitor function ....................................................................... 20-541
E-22 "Arm OUT" is not correctly displayed in monitor function ................................................................... 20-542
E-23 "Bucket CURL" is not correctly displayed in monitor function ............................................................ 20-543
E-24 "Bucket DUMP" is not correctly displayed in monitor function............................................................ 20-544
E-25 "SWING" is not correctly displayed in monitor function ...................................................................... 20-545
E-26 "Left travel" is not displayed normally in monitoring function.............................................................. 20-548
E-27 "Right travel" is not displayed normally in monitoring function ........................................................... 20-550
E-28 "Service" is not correctly displayed in monitor function ...................................................................... 20-552
E-29 Air conditioner does not work ............................................................................................................. 20-554
E-30 Step light does not light up or go off ................................................................................................... 20-555
E-31 Electric grease gun does not operate................................................................................................. 20-560
E-32 Travel alarm does not sound or does not stop sounding.................................................................... 20-562
PC750, 800-7 20-501

(1)
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)

Connection table of circuit breakers
a This connection table shows the devices to which each power supply of the circuit breakers supplies power
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
first to see if the power is supplied normally.
Type of power Circuit breaker Circuit breaker

Destination of power
supply No. capacity
1 40A Fuse box (Fuses No. 1 – 15)
Switch power supply 2 20A Boom working lamp, right head lamp
(Battery relay 3 20A Grease pump
terminal M) 4 20A Pump controller power source
5 20A Head lamp on cab
Constant power 6 20A Starting switch and engine controller (Power supply control)
supply 7 20A Engine controller power supply relay (Power supply drive)
(Battery relay 8 20A Monitor panel
terminal B) 9 20A Fuse box (Fuses No. 16 – 20)
20-502 PC750, 800-7

(1)
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)
Connection table of fuse boxes

a This connection table shows the devices to which each power supply of the fuse boxes supplies power (A
switch power supply is a device which supplies power while the starting switch is at the ON position and a
constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting for a displayed code, you should check the fuse boxes to see if the
Type of power
Fuse No. Fuse capacity Destination of power
supply
TVC solenoid (for emergency pump drive)
1 10A
Swing holding brake solenoid (for swing brake release)
Starting motor cut-out relay
2 10A Machine push-up solenoid
Switch power supply Boom shockless solenoid
(Circuit breaker 1) 3 10A PPC lock solenoid
Cigarette lighter
4 20A
Windshield washer motor
Horn
5 10A
Flash light
6 10A (Spare)
7 10A Rotary lamp
Switch power supply
8 10A (Spare)
(Circuit breaker 1)
9 10A Radio
10 20A Monitor panel
11 25A Air conditioner unit
12 20A (Spare)
Switch power supply
13 20A (Spare)
(Circuit breaker 1)
14 10A Service power supply (M32 connector)
15 10A DC/DC converter
16 10A Radio
17 10A —
Constant power 18 10A (Engine compartment lamp)
supply 19 10A Room lamp
(Circuit breaker 9) Step light
20 10A Pump controller power source (for step light)
Step light switch
PC750, 800-7 20-503

(1)
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

a The following information are edited and contained in the "Information Contained in Troubleshooting Table".
You are required to proceed with troubleshooting after fully grasping the contents.
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge "good" or "no good" about pre-
1 sumed causes.
• References for making judgement of "good" or "no good"
<Phenomena of wiring harness fault>

• Failure due to disconnection
Defective contact with connector or disconnection of wiring harness has occurred.
2
• Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in contact
Presumed cause and
with it.
Cause for presumed • Failure due to short-circuiting
failure A wiring harness that is not originally connected with a power source circuit (24 V)
(The attached No. for is in contact with it.
3
filing and reference
purpose only. It does not <Points to remember in troubleshooting>
stand for any priority) 1) Connector denotation method and handling of T-adapters
Insert or connect T-adapters in the following manner, unless specifically otherwise
instructed.
• If there is no indication of (male) or (female) in the connector No., pull off a con-
4
nector and insert a T-adapter into both sides of male and female.
• If there is an indication of (male9 and (female) in the connection No., pull off a
connector and insert a T-adapter into only one side of (male) or (female).
2) Description sequence of pin No. and handling of circuit tester leads
Connect the positive lead (+) and negative lead (–) for troubleshooting in the fol-
5 lowing manner unless specifically otherwise instructed.
• Connect the positive lead (+) to a pin No. marked at the front or wiring harness.
• Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
20-504 PC750, 800-7

(1)
TROUBLESHOOTING E-1
E-1 Engine does not start (Engine does not rotate)
Failure
• The engine does not start. (Engine does not rotate)
information
Relative
• The engine starting circuit is equipped with the start lock mechanism of safety lock lever type.
information

Battery capacity position during the troubleshooting.
1
insufficient Battery voltage Electrolyte specific gravity
Above 24 V Above 1.26
Circuit breakers No. 1 or If a circuit breaker is turned OFF or a fuse is broken, the circuit probably has ground-
2
6 or fuse 3 defective ing fault (See cause 9).
position or start the engine during the troubleshooting.
Starting switch defective H15 (male) Starting switch Resistance value
3
OFF Above 1 Mz
Between (1) and (4)
ON Below 1 z
Safety lock switch
4 defective S14 (female) Safety lock lever Resistance value
(Internal short-circuiting) FREE Above 1 Mz

Between (1) and (3)
Presumed cause and
LOCK Below 1 z
Starting motor cut-out R11 (female) and R13 (female) Resistance value
5 relay defective
Between (1) and (2) 100 – 500 z
(Internal defect)
Between (3) and (5) Above 1 Mz
Between (3) and (6) Below 1 z
a Turn the engine starting switch OFF for the preparations (with the wiring harness
connected), and start the engine for troubleshooting.
Starting motor Voltage
B (Power
Between B and grounding 20 – 30 V
supply)
Starting motor defective
6 Between ST (1)
(Internal defect) S (Start) 20 – 30 V
and grounding
Between ST (2)
R (Charge) Below 1 V
and grounding
If the above voltages are normal and the starting motor does not rotate, the starting
motor has a defect in it or the engine is defective.
a Turn the engine starting switch OFF for the preparations (with only wiring harness
Alternator defective R disconnected), and hold it in the ON position during the troubleshooting.
7
(Internal short-circuiting) Alternator Voltage
Between terminal R and grounding Below 1 V
PC750, 800-7 20-505

(1)
TROUBLESHOOTING E-1

Wiring harness between battery relay terminal B and Resistance
Below 1 z
B16 value
Resistance
Wiring harness between B26, J14, and H15 (female) (1) Below 1 z
value
Wiring harness between H15 (female) (4), J01, and R11 Resistance
(female) (5) value
harness
Wiring harness between R11 (female) (3) and ST Resistance
(female) (1) value
tor) Resistance
Wiring harness between FB1-3 and S14 (male) (1) Below 1 z
value
Wiring harness between S14 (male) (3) and R11 Resistance
Below 1 z
(female) (1) value
Wiring harness between R11 (female) (2) and R13 Resistance
Below 1 z
(female) (6) value
Presumed cause and
Wiring harness between R13 (female) (3), J04, J22, and Resistance
Below 1 z
grounding value
Between wiring harness between B26, J14, and H15 Resistance
Above 1 Mz
(female) (1) and grounding value
Between wiring harness between H15 (female) (4), J01, Resistance
Above 1 Mz
and R11 (female) (5) and grounding value
Grounding fault of wiring Between wiring harness between R11 (female) (3) and Resistance
Above 1 Mz
harness ST (female) (1) and grounding value
9
(Contact with grounding Between wiring harness between FB1-3 and S14 (male) Resistance
circuit) Above 1 Mz
(1) and grounding value
Between wiring harness between S14 (male) (3) and Resistance
Above 1 Mz
Between wiring harness between R11 (female) (2) and Resistance
Above 1 Mz
Between wiring harness between R13 (female) (2) and Resistance
Above 1 Mz
10 harness Between wiring harness between ST (female) (2) and
(Contact with 24 V circuit) alternator terminal R or between ST (female) (2), J02 Voltage Below 1 V
and D01 (female) (6) or between ST (female) (2) and
P02 (female) (11) and grounding
20-506 PC750, 800-7

(1)
TROUBLESHOOTING E-1
Electrical Circuit Diagram for Engine Preheat, Start and Battery Charging
PC750, 800-7 20-507

(1)
TROUBLESHOOTING E-2
E-2 Preheater does not operate
Failure (1) When the starting switch is turned to the HEAT posi-
• The preheater does not operate.
information tion, the preheating monitor does not light up.
• The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about
Relative 30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds).
information • Input of the preheating signal (ON or OFF) can be checked in the monitoring function.

Starting switch system If the preheater does not operate (the heater unit is not warmed), carry out trouble-
1
defective shooting (2).
Presumed cause and

tive contact with connec- Wiring harness between P02 (female) (18) and J02 Resistance
Below 1 z
tor) (male) (7) value
a Turn the engine starting switch OFF for the preparations , and hold it in the OFF or
HEAT position during troubleshooting.
3 Monitor panel defective P02 Starting switch Voltage
Between (18) and OFF Below 1 V
grounding HEAT 20 – 30 V
Failure (2) When the starting switch is turned to the HEAT

• The preheater does not operate.
information position, the heater unit is not warmed.
Relative • Check that the starting motor rotates normally.
information • (If the starting motor does not rotate, carry out troubleshooting in "Engine does not start".)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF or
HEAT position during troubleshooting.
Starting switch defective H15 (male) Starting switch Resistance value
1
OFF Above 1 Mz
Between (1) and (3)
HEAT Below 1 z
a Turn the engine starting switch OFF for the preparations (with the wiring harness
connected), and hold it in the OFF or HEAT position during troubleshooting.
Continuity and
Heater relay defective Heater relay Starting switch

2 resistance value
Presumed cause and
Between coil terminal
OFF Continued
and grounding
Between contact terminals HEAT Below 1 z
Intake air heater position during the troubleshooting.
3 defective
Intake air heater Continuity
Between terminals Continued
Wiring harness between H15 (female) (3), J02, and Resistance
Below 1 z
heater relay terminal value
Disconnection of wiring Wiring harness between starting motor terminal B and Resistance
harness Below 1 z
heater relay value
tive contact with connec- Wiring harness between heater relay and intake air Resistance
Below 1 z
tor) heater value
Resistance
Wiring harness between intake air heater and engine Below 1 z
value
20-508 PC750, 800-7

(1)
TROUBLESHOOTING E-2
Electrical Circuit Diagram for Engine Preheat, Start and Battery Charging
PC750, 800-7 20-509

(1)
TROUBLESHOOTING E-3
E-3 Auto engine warm-up device does not work
Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine cooling water temperature is below
30°C, and raise the engine rotation up to 1,200 rpm.
Relative • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
information than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.
• If the engine water temperature is below 10°C, the turbocharger protection function operates to keep
the engine speed below 1,000 rpm for up to 5 seconds after the engine is started.

a Turn the starting switch ON for the troubleshooting (monitoring).
Presumed cause and
Monitoring code Item Normal display

Compare the monitor
Engine cooling water Engine cooling water
1 indication with the actual
temperature signal fault 04107 temperature
engine cooling water
(low temperature)
temperature.
If the display on the monitor panel is abnormal, carry out troubleshooting in "Engine
water thermometer does not display normally".
Engine controller If cause 1 is not detected, the engine controller may be defective. (Since trouble is in
2
defective the engine controller, troubleshooting cannot be carried out.)
20-510 PC750, 800-7

(1)
TROUBLESHOOTING E-4
E-4 Auto-decelerator does not operate
Failure
• The auto-decelerator does not operate.
information
• Since the auto-decelerator is set to 1,400 rpm, it does not operate if the fuel control dial is not set above
this level.
Relative
• Check the display on the monitor panel while the engine is running.
information
• If the display on the monitor panel is abnormal, carry out troubleshooting in "*** is not displayed nor-
mally in monitoring function".

Boom RAISE signal
1 01900 Lever operated: ON
defective Boom RAISE
Pressure switch 1 Lever in neutral: OFF
Boom LOWER signal
defective Boom LOWER
3 Arm IN signal defective 01900 Lever operated: ON
Arm IN
4 Arm OUT signal defective 01900 Lever operated: ON
Arm OUT
Bucket CURL signal

Presumed cause and
defective Bucket CURL

Bucket DUMP signal
defective Bucket DUMP
7 Swing signal defective 01900 Lever operated: ON
Swing
Left travel signal
defective Left travel
Right travel signal
defective Right travel
10 Service signal defective 01901 Lever operated: ON
Service
If causes 1 – 10 are not detected, the pump controller may be defective.
(Since trouble is in the pump controller, troubleshooting cannot be carried out.)
Engine controller If causes 1 – 10 are not detected, the engine controller may be defective.
12
defective (Since trouble is in the pump controller, troubleshooting cannot be carried out.)
PC750, 800-7 20-511

(1)
TROUBLESHOOTING E-5
E-5 All work equipment, swing and travel do not move
Failure
• All the work equipment, swing and travel do not move.
information
Relative
—
information

If the fuse is blown, there is a big possibility that grounding fault occurred in the cir-
1 Fuse No. 3 fault
cuit. (See Cause 6.)
Safety lock switch
2 defective S14 (female) Safety lock lever Resistance value
(Internal disconnection) Free Below 1 z
Between (1) and (2)
Lock Above 1 Mz
PPC lock solenoid fault position during the troubleshooting.
(Internal disconnection, V08 (male) Resistance value
3
short-circuiting, or
grounding fault) Between (1) and (2) 20 – 60 z

Presumed cause and
4 D01 fault
Disconnection of wiring Wiring harness between FB1-3 outlet and S14 (male) Resistance
harness Below 1 z
(1) value
tive contact with connec- Wiring harness from S14 (male) (2) and V08 (female) Resistance
Below 1 z
tor) (2) value
Wiring harness between V08 (female) (1) to J14 and Resistance
Below 1 z
grounding value
Between wiring harness between FB1-3 outlet and S14 Resistance
harness Above 1 Mz
6 (male) (1) and grounding value
(Contact with grounding
(GND) circuit) Wiring harness from S14 (male) (2) to V08 (female) (2),
Resistance
or between wiring harness between S14 (male) (2) and Above 1 Mz
value
20-512 PC750, 800-7

(1)
TROUBLESHOOTING E-5
Electrical Circuit Diagram for PPC Lock Solenoid
PC750, 800-7 20-513

(1)
TROUBLESHOOTING E-6
E-6 Machine push-up function does not operate normally
Failure • The machine push-up function does not

(1) The machine push-up function does not operate.
information operate normally.
Relative
• When the machine push-up function is set in the high pressure position, the solenoid is turned OFF.
information


Presumed cause and
Machine push-up switch

1 defective M38 (female) Machine push-up switch Resistance value
(Internal short-circuiting) Low pressure position Below 1 z
Between (1) and (2)
High pressure position Above 1 Mz
Short-circuiting of wiring position during troubleshooting.
2 harness Between wiring harness between M38 (female) (2), J06
(Contact with 24 V circuit) and V05 (female) (2) or between M38 (female) (2) and Voltage Below 1 V
Circuit diagram related to machine push-up solenoid
20-514 PC750, 800-7

(1)
TROUBLESHOOTING E-6
Failure • The machine push-up function does not

(2) The machine push-up function is not turned OFF.
information operate normally.
Relative
• When the machine push-up function is set in the low pressure position, the solenoid is turned ON.
information

1 Fuse No. 2 defective If the fuse is broken, the circuit probably has grounding fault (See cause 6).
Machine push-up switch
2 defective M38 (female) Machine push-up switch Resistance value
(Internal disconnection) Low pressure position Below 1 z
Between (1) and (2)
High pressure position Above 1 Mz
Machine push-up
solenoid defective
3 (Internal disconnection, V05 (male) Resistance value
short-circuiting or Between (1) and (2) 20 – 60 z
grounding fault)
Presumed cause and
Assembled-type diode position during troubleshooting.

4 D04 defective
Disconnection of wiring Wiring harness between FB1-2 outlet and M38 (male) Resistance
harness Below 1 z
(1) value
tive contact with connec- Wiring harness between M38 (male) (2), J06 and V05 Resistance
Below 1 z
Wiring harness between V05 (female) (1), J15, and Resistance
Below 1 z
grounding value
Grounding fault of wiring Between wiring harness between FB1-2 outlet and M38
Resistance
harness (male) (1) or between FB1-2 outlet and related circuits Above 1 Mz
6 value
(Contact with grounding and grounding
circuit) Between wiring harness between M38 (male) (2), J06
Resistance
and V05 (female) (2) or between M38 (male) (2) and Above 1 Mz
value
PC750, 800-7 20-515

(1)
TROUBLESHOOTING E-7
E-7 Boom shockless function does not operate normally
Failure • The boom shockless function does not oper-

(1) The boom shockless function does not operate.
information ate normally.
Relative
• When the boom shockless function is turned ON, the solenoid is turned OFF.
information

Boom shockless control Boom shockless

Presumed cause and
1 switch defective M39 (female) Resistance value

control switch
OFF Below 1 z
Between (2) and (3)
ON Above 1 Mz
2 harness Between wiring harness between M39 (male) (3), J20,
(Contact with 24 V circuit) and V09 (female) (2) or between M39 (male) (3) and Voltage Below 1 V
V10 (female) (2) or between M39 (male) (3) and D05
(female) (1) and grounding
Circuit diagram related to boom shockless solenoid
20-516 PC750, 800-7

(1)
TROUBLESHOOTING E-7
Failure • The boom shockless function does not oper-

(2) The boom shockless function is not turned OFF.
information ate normally.
Relative
• When the boom shockless function is turned OFF, the solenoid is turned ON.
information

Boom shockless control Boom shockless
2 switch defective M39 (female) Resistance value
control switch
OFF Below 1 z
Between (2) and (3)
ON Above 1 Mz
Boom shockless solenoid position during the troubleshooting.
defective V09 (male) and V10 (male) Resistance value
3
short-circuiting) Between (1) and (2) 20 – 60 z
Presumed cause and

4 D05 defective
Disconnection of wiring Wiring harness between FB1-2 outlet and M39 (male) Resistance
Below 1 z
harness (2) value
5 (Disconnection or defec- Wiring harness between M39 (male) (3) and V09
(female) (2) or between M39 (male) (3) and V10 Below 1 z
tor) value
(female) (2).
Wiring harness between V09 (female) (1), V10 (female) Resistance
Below 1 z
(1), J14, and grounding value
Grounding fault of wiring Between wiring harness between FB1-2 outlet and M39
Resistance
harness (female) (1) or between FB1-2 outlet and related circuits Above 1 Mz
6 value
(Contact with grounding and grounding
circuit) Between wiring harness between M39 (male) (3), V09
Resistance
(female) (2) and V10 (female) (2) or between M39 Above 1 Mz
value
(male) (3) and D05 (female) (1) and grounding
PC750, 800-7 20-517

(1)
TROUBLESHOOTING E-8
E-8 Any item is not displayed on monitor panel
Failure • Any item is not displayed on the monitor When the starting switch is turned ON, any item is not
information panel. displayed on the monitor panel.
Relative
information

Circuit breaker No. 1 or If the circuit breaker is turned OFF or the fuse is broken, the circuit probably has
1
fuse No. 10 defective grounding fault (See cause 3).
Disconnection of wiring Wiring harness between P01 (female) (1), (2) and FB1- Resistance
harness Below 1 z
10 outlet value
Wiring harness between FB1 inlet and B21 Below 1 z
tor) value
Presumed cause and
Wiring harness between B11 and battery relay terminal Resistance

Below 1 z
M value
harness Between wiring harness between P01 (female) (1), (2) Resistance
3 Above 1 Mz
(Contact with grounding and FB1-10 outlet and grounding value
circuit) Between wiring harness between FB1 inlet and B21 and Resistance
Above 1 Mz
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON or
OFF position during troubleshooting.
P01 (female) Starting switch Voltage, Resistance value
4 Monitor panel defective Between (1), (2)
ON Voltage: 20 – 30 V
and grounding
Between (6), (7) Resistance value:
OFF
and grounding Below 1 z
Circuit diagram related to monitor panel power supply
20-518 PC750, 800-7

(1)
TROUBLESHOOTING E-9, E-10
E-9 Part of display on monitor panel is missing
Failure Part of the display in the monitor panel is missing during

• Part of display on monitor panel is missing
information starting switch in ON.
Relative
—
information

Presumed cause and
a Turn the starting switch ON during the troubleshooting.
If all the LCD (Liquid Crystal Display) in the monitor panel light up (i.e. the screen
1 Monitor panel LCD fault
becomes totally white) by the following switching operation, then the monitor panel is
normal.
• Switching operation: [ ] + [ A ] (push swiches simultaneously.)
Monitor panel If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in
2
defective the monitor panel, troubleshooting cannot be carried out.)
E-10 Monitor panel displays contents irrelevant to the model
Failure
• The monitor panels displays contents that have nothing to do with the model on which it is installed.
information
Relative
—
information

Presumed cause and
a Turn the starting switch in ON during the troubleshooting (monitoring).
Model code signal fault Monitoring code Item Normal display

1
(Internal failure) 00200 Controller model code PC750-a
If the display on the monitor panel is normal, troubleshoot Error Code [E217].
Monitor panel If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in
2
defective the monitor panel, troubleshooting cannot be carried out.)
PC750, 800-7 20-519

(1)
TROUBLESHOOTING E-9, E-10
E-11 Fuel level monitor red lamp lights up while engine is running
Failure
• The fuel level monitor red lamp lighted up while the engine was running.
information
Relative
• If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
information

Fuel level lowered
1 (system in normal Check the fuel level in the fuel tank. If it is low, add fuel.
condition)
Fuel level sensor fault P06 (male) Fuel level Resistance value
2
Presumed cause and
FULL (Upper limit) Approx. 12 z
EMPTY (Lower limit) 85 – 110 z
tive contact with connec- Wiring harness between P02 (female) (2) and P06 Resistance
Max. 1 z
4 Monitor panel defective P02 (female) Fuel level Resistance value
Electrical Circuit Diagram for Fuel Level Sensor
20-520 PC750, 800-7

(1)
TROUBLESHOOTING E-12
E-12 Engine water thermometer does not display normally
(1) While the engine water temperature rises normally,

the thermometer does not rise above the white
Failure • Engine water thermometer does not display
range (C).
information normally
(2) While the engine water temperature is stabilized nor-
mally, the thermometer rises up to the red range (H).
• The signal of the engine water high temperature sensor for the water thermometer is received from the
engine controller through the communication line.
• If the engine water high temperature sensor system becomes defective, error code [E934] may be dis-
Relative
played.
information
• Input from the engine water high temperature sensor (voltage and temperature) can be checked in the
monitoring function. (Code No. 04106: Engine water sensor voltage Hi, 04102: Engine water tempera-
ture (High temperature))

Engine water high a Turn the engine starting switch OFF for the preparations, and turn to ON or keep
temperature sensor the engine running during the troubleshooting.
defective TWH (male) Resistance value
1
(Internal disconnection,
short-circuiting or Between (1) and (2) 3.5 k – 90 kz
grounding fault) Between (1), (2) and grounding Above 1 Mz
harness
Wiring harness between E12 (female) (27) and TWH Resistance
(female) (1) value

Wiring harness between E12 (female) (39), J09, and Resistance
Presumed cause and
tor) Below 1 z
TWH (female) (2) value
3
circuit) Above 1 Mz
TWH (female) (1) and grounding value
4 harness
(Contact with 24 V circuit) Between wiring harness between E12 (female) (27) and Voltage Below 1 V
TWH (female) (1) and grounding
5
defective
Between (27) and (39) 3.5 k – 90 kz
If causes 1 – 5 are not detected, the monitor panel may be defective. (Since trouble
is in the monitor panel, troubleshooting cannot be carried out.)
20-522 PC750, 800-7

(1)
Circuit diagram related to engine water high temperature sensor
PC750, 800-7 20-523

(1)
E-13 Hydraulic oil temperature gauge does not display correctly
• Hydraulic oil temperature rises normally, but the dis-

Failure • Hydraulic oil temperature gauge does not play does not exceed the white range (C).
information display correctly • Hydraulic oil temperature remains stable, but the dis-
play rises up the red range (H).
Relative • Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
information (Code No. 04401: Hydraulic oil temperature)

Hydraulic oil temperature
sensor fault
1 (Internal disconnection, P10 (male) Hydraulic oil temperature Resistance value
short-circuiting or Between (1) and (2) 90 – 3.5 kz
grounding fault) 10 – 100°C
Presumed cause and standard value in normalcy
harness
(female) (1) value
tor) Wiring harness between P02 (female) (13) and P10 Resistance
Max. 1 z
(female) (2) value
3
(GND) circuit) Min. 1 Mz
4 harness
(Contact with 24 V circuit) Between wiring harness between P02 (female) (12) and Voltage Max. 1 V
P02 (female) Hydraulic oil temperature Resistance value
Between (12) and (13) 90 – 3.5 kz
Between (12) and 10 – 100°C
Min. 1 Mz
grounding
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
20-524 PC750, 800-7

(1)
E-14 Fuel gauge does not display correctly
• Though fuel was refilled, the display does not exceed

Failure the red range (E).
• Fuel gauge does not display correctly
information • Though the remaining fuel level is low, the display
does not drop below the green range (F).
Relative • Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
information (Code No. 04200: Fuel sensor voltage)

Fuel level sensor fault
1 (Internal disconnection or P06 (male) Fuel level Resistance value
grounding fault) FULL (Upper limit) Approx. 12 z
Presumed cause and
tive contact with connec- Max. 1 z

3
(GND) circuit) Min. 1 Mz
4 harness
(Contact with 24 V circuit) Between wiring harness between P02 (female) (2) and
Voltage Max. 1 V
5 Monitor panel defective P02 (female) Fuel level Resistance value
Electrical Circuit Diagram for Fuel Level Sensor
PC750, 800-7 20-525

(1)
E-15 Swing lock monitor does not display correctly
(1) Though the swing lock switch was turned ON, the
Failure swing lock monitor does not light up.
• Swing lock monitor does not display correctly
information (2) Though the swing lock switch was turned OFF, the
swing lock monitor lights up.
Relative • Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.

Swing lock switch fault
1 (Internal disconnection or X05 (female) Swing lock switch Resistance value
short-circuiting) OFF Above 1 Mz
Between (1) and (2)
ON Below 1 z
harness
Wiring harness from P02 (female) (17) to J07 and X05 Resistance
(male) (1) value

Presumed cause and
tor) Wiring harness from X05 (male) (2) to J08 and ground- Resistance
Below 1 z
ing value
harness
3 Between wiring harness from P02 (female) (17) to J07
(GND) circuit) and X05 (male) (1), or between P02 (female) (17) to Above 1 Mz
value
4 harness Between wiring harness from P02 (female) (17) to J07
(Contact with 24 V circuit) and X05 (male) (1), or between P02 (female) (17) to Voltage Below 1 V
5 Monitor panel defective P02 Swing lock switch Voltage
Between (17) and OFF 20 – 30 V
grounding ON Below 1 V
20-526 PC750, 800-7

(1)
Electrical Circuit Diagram for Swing Holding Brake
PC750, 800-7 20-527

(1)
E-16 When monitor switch is operated, nothing is displayed
Failure • When monitor switch is operated, nothing is (1) When mode selector switch is operated, working
information displayed. mode monitor is not displayed.
Relative
—
information

cause and
standard value Monitor panel
1 As this is an internal failure, troubleshooting cannot be conducted.
in normalcy defective
Failure • When monitor switch is operated, nothing is (2) When LCD monitor adjustment switch is operated,
information displayed. mode selection screen is not displayed.
Relative
—
information

cause and
Failure • When monitor switch is operated, nothing is (3) When maintenance switch is operated, item selec-
information displayed. tion screen is not displayed.
Relative
—
information

cause and
Failure • When monitor switch is operated, nothing is (4) When automatic deceleration switch is operated,
information displayed. automatic deceleration monitor is not displayed.
Relative • When the automatic decelerator does not operate either, conduct the troubleshooting for "Auto-deceler-
information tor does not operate".

cause and
Failure • When monitor switch is operated, nothing is (5) When travel speed selector switch is operated,
information displayed. travel speed monitor is not displayed.
Relative
information

cause and
20-528 PC750, 800-7

(1)
Failure • When monitor switch is operated, nothing is (6) When wiper switch is operated, wiper monitor is not
information displayed. displayed.
Relative • When the wiper does not operate either, conduct the troubleshooting for "Windshield wiper and window
information washer do not work".

cause and
PC750, 800-7 20-529

(1)
E-17 Windshield wiper and window washer do not work
Failure • Windshield wiper and window washer do not

(1) The upper windshield wiper does not operate
information work
Relative
information

Upper wiper motor position during the troubleshooting.
1 defective
W04 (female) Continuity and resistance value
Between (3) and (1) Continued

Presumed cause and
harness
(male) (3) value
tor) Resistance
value
3 Monitor panel defective P01 Wiper switch Voltage
OFF Below 3 V
ON 20 – 30 V (Note)
Note: When the upper wiper and lower wiper are operated simultaneously: Below 3 V 20 – 30 V (at regular
intervals)
20-530 PC750, 800-7

(1)

(2) Lower windshield wiper does not operate.
information work
Relative
information

Lower wiper switch
1 defective W06 (female) Lowe wiper switch Resistance value
(Internal disconnection) OFF Above 1 Mz
Between (1) and (2)
ON Below 1 z
Lower wiper motor position during the troubleshooting.
2 defective

Presumed cause and

(male) (1) value
harness
Wiring harness between W06 (male) (2), J05, J22, and Resistance
grounding value
tor) Wiring harness between P01 (female) (10), J04, and Resistance
Below 1 z
W05 (male) (3) value
Wiring harness between W05 (male) (1), J05, J22, and Resistance
Below 1 z
grounding value
Monitor panel defective
(Lower wiper switch P02 Lower wiper switch Voltage
system) Between (15) and OFF 20 – 30 V
grounding ON Below 1 V
4
Monitor panel defective
(Lower wiper motor P01 Lower wiper switch Voltage
system) Between (10) and OFF Below 3 V
grounding ON 20 – 30 V (Note)
Note: When the upper wiper and lower wiper are operated simultaneously: Below 3 V 20 – 30 V (at regular
intervals)
PC750, 800-7 20-531

(1)
Circuit diagram related to wiper motor (double-wiper specification)
20-532 PC750, 800-7

(1)
Single windshield wiper spec.

(3) The windshield wiper does not work.
information work.
Relative
information

Window rear limit switch position during the troubleshooting.
fault W03 (female) Front window Resistance value
1
short-circuiting) When installed at front Above 1 Mz
Between (1) and (2)
When retracted at rear Below 1 z
Windshield wiper motor position during the troubleshooting.
2 fault
harness
Wiring harness between P01 (male) (9) and W04 Resistance
Presumed cause and

(female) (3) value
tor) Wiring harness between P01 (male) (10) and W04 Resistance
Below 1 z
(female) (1) value
4
(GND) circuit) Above 1 Mz
W03 (male) (2) value
Monitor panel fault
(Window rear limit switch P02 Front window Voltage
system) Between (15) and When installed at front 20 – 30 V
grounding When retracted at rear Below 1 V
5 a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Monitor panel fault P01 Windshield wiper switch Voltage
(Windshield wiper motor
system) Between (9) and grounding, OFF Below 3 V
Between (10) and Below 3 V 20 – 30 V
grounding ON
(Constant cycle)
20-534 PC750, 800-7

(1)
Electrical Circuit Diagram for Windshield Wiper Motor (Single windshield wiper spec.)
PC750, 800-7 20-535

(1)

(4) Windshield washer does not operate.
information work.
Relative
—
information

1 Fuse No. 4 defective If fuse is broken, the circuit probably has grounding fault, etc. (See cause 4.)
Washer motor defective
2 (Internal disconnection or M28 (male) Resistance value
grounding fault) Between (1) and (2) 5 – 20 z

Presumed cause and
harness
Wiring harness from FB1-4 outlet to J04 and M28 Resistance
(female) (1) value
tor) Wiring harness from M28 (female) (2) and P01 (female) Resistance
Below 1 z
(3) value
harness
4 Between wiring harness from FB1-4 outlet to J04 and
circuit) M28 (female) (1), or FB1-4 outlet to D05 (female) (3), Above 1 Mz
value
and to other relative circuits and grounding
Monitor panel P01 Windshield washer switch Voltage
5
defective
OFF 20 – 30 V
ON Below 1 V
20-536 PC750, 800-7

(1)
Electrical Circuit Diagram for Window Washer Motor
PC750, 800-7 20-537

(1)
E-18 Alarming buzzer cannot be cancelled
Failure
• The alarming buzzer cannot be cancelled.
information
Relative • Input from the alarming buzzer stop switch (ON or OFF) can be confirmed in the monitor function.

Alarming buzzer stop Alarming buzzer
1 switch fault P03 (female) Resistance value
stop switch
Release Above 1 Mz
Between (1) and (2)
Depress Below 1 z

Presumed cause and
harness
(male) (1) value
tor) Resistance
Wiring harness from P03 (male) (2) to J08 to grounding Below 1 z
value
3 harness
(Contact with 24 V circuit) Between wiring harness between P02 (female) (16) and
Voltage Below 1 V
P03 (male) (1) and grounding
Alarming buzzer stop
4 Monitor panel fault P02 Voltage
switch
Between (16) and Release 20 – 30 V
grounding Depress Below 1 V
Electrical Circuit Diagram for Alarming Buzzer Stop Switch
20-538 PC750, 800-7

(1)
E-19 "Boom RAISE" is not correctly displayed in monitor function
Failure • "Boom RAISE" is not correctly displayed in mon- "Boom RAISE" is not correctly displayed in the moni-
information itor function tor function on the monitor panel.
Relative
—
information

Boom RAISE PPC
hydraulic switch fault R.H. work equipment
(Internal disconnection or control lever
short-circuiting) NEUTRAL Above 1 Mz
Between (1) and (2)
Boom RAISE Below 1 z
harness

(female) (2) value
Presumed cause and

tor) Wiring harness between S02 (female) (1) to J12 to J11 Resistance
Below 1 z
and grounding value
3
S02 (female) (2) and grounding value
4 harness
(Contact with 24 V circuit) Between wiring harness between C03 (female) (10) and
Voltage Below 1 V
a Turn the engine starting switch OFF for the preparations, and start the engine
R.H. work equipment
control lever
Between (10) and NEUTRAL 20 – 30 V
grounding Boom RAISE Below 1 V
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC750, 800-7 20-539

(1)
E-20 "Boom LOWER" is not correctly displayed in monitor function
Failure • "Boom LOWER" is not correctly displayed in "Boom LOWER" is not correctly displayed in the
information monitor function monitor function on the monitor panel.
Relative
—
information

Boom LOWER PPC
Between (1) and (2)
Boom LOWER Below 1 z
harness

(female) (2) value
Presumed cause and

Below 1 z
and grounding value
3
4 harness
Voltage Below 1 V
R.H. work equipment
control lever
grounding Boom LOWER Below 1 V
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
20-540 PC750, 800-7

(1)
E-21 "Arm IN" is not correctly displayed in monitor function
Failure • "Arm IN" is not correctly displayed in monitor "Arm IN" is not correctly displayed in the monitor
information function function (special function) on the monitor panel.
Relative
—
information

Arm IN PPC hydraulic
switch fault L.H. work equipment
Between (1) and (2)
Arm IN Below 1 z
harness

(female) (2) value
Presumed cause and

Below 1 z
and grounding value
3
4 harness
Voltage Below 1 V
L.H. work equipment
control lever
Between (30) and ground- NEUTRAL 20 – 30 V
ing Arm IN Below 1 V
Electrical Circuit Diagram for Arm IN PPC Hydraulic Switch
PC750, 800-7 20-541

(1)
E-22 "Arm OUT" is not correctly displayed in monitor function
Failure • "Arm OUT" is not correctly displayed in monitor "Arm OUT" is not correctly displayed in the monitor
Relative
—
information

Arm OUT PPC hydraulic
switch defect L.H. work equipment
(Internal disconnection control lever
and short-circuiting) NEUTRAL Above 1 Mz
Between (1) and (2)
Arm OUT Below 1 z
harness

(female) (2) value
Presumed cause and

Below 1 z
and grounding value
3
4 harness
Voltage Below 1 V
L.H. work equipment
control lever
grounding Arm OUT Below 1 V
Electrical Circuit Diagram for Arm OUT PPC Hydraulic Switch
20-542 PC750, 800-7

(1)
E-23 "Bucket CURL" is not correctly displayed in monitor function
Failure • "Bucket CURL" is not correctly displayed in "Bucket CURL" is not correctly displayed in the mon-
information monitor function itor function (special function) on the monitor panel.
Relative
—
information

Bucket CURL PPC
Between (1) and (2)
Bucket CURL Below 1 z
harness

(female) (2) value
Presumed cause and

Below 1 z
and grounding value
3
4 harness
Voltage Below 1 V
R.H. work equipment
control lever
NEUTRAL 20 – 30 V
Bucket CURL Below 1 V
Electrical Circuit Diagram for Bucket CURL PPC hydraulic Switch
PC750, 800-7 20-543

(1)
E-24 "Bucket DUMP" is not correctly displayed in monitor function
Failure "Bucket DUMP" is not correctly displayed in moni- "Bucket DUMP" is not correctly displayed in the mon-
information tor function itor function (special function) on the monitor panel.
Relative
—
information

Bucket DUMP PPC
Between (1) and (2)
Bucket DUMP Below 1 z
harness

(female) (2) value
Presumed cause and

Below 1 z
and grounding value
3
4 harness
Voltage Below 1 V
R.H. work equipment
control lever
grounding Bucket DUMP Below 1 V
Electrical Circuit Diagram for Bucket DUMP PPC hydraulic Switch
20-544 PC750, 800-7

(1)
E-25 "SWING" is not correctly displayed in monitor function
Failure • "SWING" is not correctly displayed in monitor "SWING" is not correctly displayed in the monitor
Relative
—
information

Swing PPC hydraulic
switch, left, fault L.H. work equipment
Between (1) and (2)
Swing Left Below 1 z
Swing PPC hydraulic
switch, right, fault L.H. work equipment
Between (1) and (2)
Swing Right Below 1 z
Wiring harness between C03 (female) (29) to J11 and

Presumed cause and

harness S08 (female) (2), or wiring harness between C03 Below 1 z
value
3 (Disconnection or defec- (female) (29) and S10 (female) (2)
tive contact with connec- Wiring harness between S08 (female) (1) to J11 and Resistance
tor) Below 1 z
grounding value
Wiring harness between S10 (female) (1) to J12 to J11 Resistance
Below 1 z
and grounding value
harness
4 Wiring harness between C03 (female) (29) to J11 and
(GND) circuit) S08 (female) (2), or wiring harness between C03 Above 1 Mz
value
(female) (29) and S10 (female) (2) and grounding
5 harness Wiring harness between C03 (female) (29) to J11 and
(Contact with 24 V circuit) S08 (female) (2), or wiring harness between C03 Voltage Below 1 V
(female) (29) and S10 (female) (2) and grounding
L.H. work equipment
control lever
grounding Swing Right or left Below 1 V
PC750, 800-7 20-545

(1)
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
20-546 PC750, 800-7

(1)
E-26 "Left travel" is not displayed normally in monitoring function
Failure • "Left travel" is not displayed normally in the "Left travel" is not displayed normally in the monitor-
information monitoring function. ing function (special function) of the monitor panel.
Relative
information

Left travel forward PPC
oil pressure switch
1 defective S12 (male) Left travel lever Resistance value
(Internal disconnection or Neutral Above 1 Mz
short-circuiting) Between (1) and (2)
Forward Below 1 z
Left travel reverse PPC
oil pressure switch
2 defective S13 (male) Left travel lever Resistance value
Reverse Below 1 z
Disconnection of wiring Wiring harness between C02 (female) (16), J19, and
Resistance
Presumed cause and
harness S12 (female) (2) or between C02 (female) (16) and S13 Below 1 z
value
3 (Disconnection or defec- (female) (2)
tive contact with connec- Wiring harness between S12 (female) (1), J13, J11, and Resistance
tor) Below 1 z
grounding value
Wiring harness between S13 (female) (1), J13, J11, and Resistance
Below 1 z
grounding value
harness
circuit) J19, and S12 (female) (2) or between C02 (female) (16) Above 1 Mz
value
and S13 (female) (2) and grounding
(Contact with 24 V circuit) J19, and S12 (female) (2) or between C02 (female) (16) Voltage Below 1 V
6 Pump controller defective C02 Left travel lever Voltage
Between (16) and Neutral 20 – 30 V
grounding Forward or reverse Below 1 V
20-548 PC750, 800-7

(1)
Circuit diagram related to left travel forward PPC oil pressure switch and left travel reverse
PPC oil pressure switch
PC750, 800-7 20-549

(1)
E-27 "Right travel" is not displayed normally in monitoring function
Failure • "Right travel" is not displayed normally in moni- "Right travel" is not displayed normally in the moni-
information toring function toring function (special function) of the monitor panel.
Relative
information

Right travel forward PPC
oil pressure switch
1 defective S01 (male) Right travel lever Resistance value
Forward Below 1 z
Right travel reverse PPC
oil pressure switch
2 defective S11 (male) Right travel lever Resistance value
Reverse Below 1 z
Disconnection of wiring Wiring harness between C03 (female) (39), J19, and
Resistance
Presumed cause and
harness S01 (female) (2) or between C03 (female) (39) and S11 Below 1 z
value
3 (Disconnection or defec- (female) (2)
tive contact with connec- Wiring harness between S01 (female) (1), J13, J11, and Resistance
tor) Below 1 z
grounding value
Wiring harness between S11 (female) (1), J13, J11, and Resistance
Below 1 z
grounding value
harness
circuit) J19, and S01 (female) (2) or between C03 (female) (39) Above 1 Mz
value
(Contact with 24 V circuit) J19, and S01 (female) (2) or between C03 (female) (39) Voltage Below 1 V
6 Pump controller defective C02 Right travel lever Voltage
Between (39) and Neutral 20 – 30 V
grounding Forward or reverse Below 1 V
20-550 PC750, 800-7

(1)
Circuit diagram related to right travel forward PPC oil pressure switch and right travel reverse
PPC oil pressure switch
PC750, 800-7 20-551

(1)
E-28 "Service" is not correctly displayed in monitor function
When attachment is installed
Failure • "Service" is not correctly displayed in monitor "Service" is not correctly displayed in the monitor func-
information function tion (special function) on the monitor panel.
Relative
—
information

Service PPC hydraulic running during the troubleshooting.
switch fault S09 (male) Service pedal Resistance value
1
Between (1) and (2)
Operated Below 1 z
harness

(female) (2) value
Presumed cause and

Below 1 z
and grounding value
3
(Contact with grounding Wiring harness between C02 (female) (35) and S09 Resistance
(female) (2) value
4 harness
(Contact with 24 V circuit) Wiring harness between C02 (female) (35) and S09 Voltage Below 1 V
(female) (2) and grounding
5 Pump controller defective C02 Service pedal Voltage
grounding Operated Below 1 V
20-552 PC750, 800-7

(1)
Electrical Circuit Diagram for Service PPC hydraulic Switch
PC750, 800-7 20-553

(1)
E-29 Air conditioner does not work
Failure
• The air conditioner does not work.
information
Relative
information

When fuse is blown, there is a big possibility that grounding fault occurred in the cir-
1 Fuse No. 11 fault
cuit. (See Cause 3.)
harness
Wiring harness between FB1-11 outlet and M26 (male) Resistance

(4) (5) value
Presumed cause and

tor) Resistance
Wiring harness between M26 (male) (8) and grounding Below 1 z
value
3
(Contact with grounding Between wiring harness between FB1-11 outlet and
(GND) circuit) Voltage Above 1 Mz
M26 (male) (4) (5) and grounding
Air conditioner unit M26 Voltage
4
defective Between (4) (5) and (8) 20 – 30 V
If the above voltages are normal and the air conditioner does not operate, the air con-
ditioner unit is defective.
Electrical Circuit Diagram for Air Conditioner
20-554 PC750, 800-7

(1)
E-30 Step light does not light up or go off
Failure (1) When the switch is pressed, the light does not keep
• The step light does not light up or go off.
information lighting up for 1 minute.
Relative
information

2 Step light defective The step light may be defective. Check the bulb directly for breakage.
Step light switch
3 defective M81 (male) Step light switch Resistance value
(Internal disconnection) Released Above 1 Mz
Between (1) and (2)
Pressed Below 1 z
Step light power source position during the troubleshooting.
4 holding relay defective
(Internal defect) Replace the step light power source holding relay with another one.
R14
If trouble is repaired, the relay is defective.
5
(Internal defect) Replace the step light relay with another one. If trouble is repaired, the
R15
relay is defective.
Presumed cause and
Wiring harness between FB1-20 outlet and M81
Resistance
(female) (2) or between FB1-20 outlet and R14 (female) Below 1 z
value
(3) or between FB1-20 outlet and R15 (female) (3)
Wiring harness between M81 (female) (1), J07, and C01
Resistance
(female) (24) or between M81 (female) (1), D04 and Below 1 z
value
R14 (female) (1)
Wiring harness between C03 (female) (5), D02, and Resistance
Below 1 z
Disconnection of wiring R14 (female) (1) value
harness Wiring harness between R14 (female) (2), J04, J22, and Resistance
grounding value
tor) Wiring harness between R14 (female) (5), J07, and C03 Resistance
Below 1 z
(female) (1), (2), (11), (12), (14), and (24) value
Wiring harness between C03 (female) (15) and R15 Resistance
Below 1 z
(female) (1) value
Wiring harness between R15 (female) (2), J04, J22, and Resistance
Below 1 z
grounding value
Wiring harness between R15 (female) (5) and M75 Resistance
Below 1 z
(female) (1) value
Wiring harness between M75 (female) (2) and ground- Resistance
Below 1 z
ing value
PC750, 800-7 20-555

(1)

Between wiring harness between FB1-20 outlet and
M81 (female) (2) or between FB1-20 outlet and R14 Resistance
Above 1 Mz
(female) (3) or between FB1-20 outlet and R15 (female) value
(3) and grounding
Between wiring harness between M81 (female) (1), J07,
harness
7 and C01 (female) (24) or between M81 (female) (1), Resistance
(Contact with grounding Above 1 Mz
D04 and R14 (female) (1) or between M81 (female) (1) value
circuit)
Between wiring harness between R14 (female) (5), J07,
Resistance
and C03 (female) (1), (2), (11), (12), (14), and (24) and Above 1 Mz
value
grounding
Presumed cause and
Between wiring harness between R15 (female) (5), M75 Resistance

Above 1 Mz
(female) (1) and grounding value
Pump controller defective
(Step light switch input C01 Step light switch Voltage
system) Between (24) and Released Below 1 V
grounding Pressed 20 – 30 V
(Step light power source C03 Step light switch Voltage
8 holding relay output Released Below 1 V
system) Between (5) and grounding 20 – 30 V
Pressed
(60 seconds)
Pump controller defective C03 Step light switch Voltage
(Step light relay output
system) Released Below 1 V
Between (15) and
grounding 20 – 30 V
Pressed
(60 seconds)
20-556 PC750, 800-7

(1)
Failure
• The step light does not light up or go off. (2) While the switch is not pressed, the light lights up.
information
Relative
information

Step light switch
1 defective M81 (male) Step light switch Resistance value
(Internal disconnection) Released Above 1 Mz
Between (1) and (2)
Pressed Below 1 z
Step light power source position during the troubleshooting.
2 holding relay defective
(Internal defect) Replace the step light power source holding relay with another one.
R14
If trouble is repaired, the relay is defective.
3
(Internal defect) Replace the step light relay with another one. If trouble is repaired, the
R15
relay is defective.
Between wiring harness between M81 (female) (1), J07,

Presumed cause and
Short-circuiting of wiring and C01 (female) (24) or between M81 (female) (1), Voltage Below 1 V
4 harness D04, and R14 (female) (1) and grounding
(Contact with 24 V circuit) Between wiring harness between C03 (female) (5), D02,
Voltage Below 1 V
and R14 (female) (1) and grounding
Voltage Below 1 V
R15 (female) (1)
(Step light switch input C01 Step light switch Voltage
system) Between (24) and Released Below 1 V
grounding Pressed 20 – 30 V
(Step light power source C03 Step light switch Voltage
5 holding relay output Released Below 1 V
system) Between (5) and grounding 20 – 30 V
Pressed
(60 seconds)
Pump controller defective C03 Step light switch Voltage
(Step light relay output
system) Released Below 1 V
Between (15) and
grounding 20 – 30 V
Pressed
(60 seconds)
PC750, 800-7 20-557

(1)
Circuit diagram related to step light
20-558 PC750, 800-7

(1)
E-31 Electric grease gun does not operate
Failure
• The electric grease gun does not operate.
information
Relative
information

Circuit breaker No. 3 If the circuit breaker is turned OFF, the circuit probably has grounding fault
1
defective (See cause 4).
Grease gun remote
2 switch defective G12 (female) Remote switch Resistance value
(Internal disconnection) OFF Above 1 Mz
Between (1) and (2)
ON Below 1 z
Presumed cause and

harness Wiring harness between B23 and G12 (male) (1) Below 1 z
value
tive contact with connec- Wiring harness between G12 (male) (2) and G11 (male) Resistance
Below 1 z
tor) (1) value
Resistance
Wiring harness between G11 (male) (2) and grounding Below 1 z
value
harness Between wiring harness between B23 and G12 (male) Resistance
4 Above 1 Mz
(Contact with grounding (1) and grounding value
circuit) Between wiring harness between G12 (male) (2) and Resistance
Above 1 Mz
G11 (male) (1) and grounding value
If causes 1 – 4 are not detected, the grease pump may be defective. (Since trouble
5 Grease pump defective
is in the grease pump, troubleshooting cannot be carried out.)
20-560 PC750, 800-7

(1)
Circuit diagram related to electric grease gun
PC750, 800-7 20-561

(1)
E-32 Travel alarm does not sound or does not stop sounding
(1) The alarm does not sound while the machine is trav-
Failure • The travel alarm does not sound or does not
eling.
information stop sounding.
(2) The alarm sounds while the machine is stopped.
Relative
information

01901 Lever operated: ON
Left travel
1 Travel signal defective Pressure switch 2 Lever in neutral: OFF
01900 Lever operated: ON
Right travel
If the display on the monitor panel is abnormal, carry out troubleshooting in "*** is not
displayed normally in monitoring function".
F01 (female) Travel lever Voltage

Travel alarm defective
Presumed cause and
2 Neutral Below 1 V
(Internal defect) Between (1) and (2)
If the above voltages are normal and the travel alarm does not sound, the travel
alarm is defective.
harness
Wiring harness between C03 (female) (8) and F01 Resistance
(female) (1) value
tor) Wiring harness between F01 (female) (2), J21, and Resistance
Below 1 z
grounding value
4 harness
(Contact with 24 V circuit) Between wiring harness between C03 (female) (8) and Voltage Below 1 V
F01 (female) (1) and grounding
5 Pump controller defective C03 Travel lever Voltage
Neutral Below 1 V
20-562 PC750, 800-7

(1)
Circuit diagram related to travel alarm
PC750, 800-7 20-563

(1)
TROUBLESHOOTING OF HYDRAULIC
AND MECHANICAL SYSTEM (H MODE)
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)............. 20-602

INFORMATION IN TROUBLESHOOTING TABLE ..................................................................................... 20-607
H-1 Speed or power of all work equipment, travel, and swing is low .......................................................... 20-608
H-2 Engine speed lowers remarkably or engine stalls ................................................................................ 20-610
H-3 All work equipment, travel, and swing systems do not work ................................................................ 20- 611
H-4 Abnormal sound is heard from around pump ....................................................................................... 20-612
H-5 Boom speed or power is low ................................................................................................................ 20-613
H-6 Speed or power of arm is low............................................................................................................... 20-615
H-7 Speed or power of bucket is low .......................................................................................................... 20-616
H-8 Boom does not move ........................................................................................................................... 20-617
H-9 Arm does not move .............................................................................................................................. 20-617
H-10 Bucket does not move........................................................................................................................ 20-617
H-11 Hydraulic drift of work equipment is large........................................................................................... 20-618
H-12 Time lag of work equipment is large................................................................................................... 20-620
H-13 Heavy lift function does not operate or stop ....................................................................................... 20-621
H-14 Machine push-up function does not operate or stop .......................................................................... 20-621
H-15 Boom shockless function cannot be turned ON or OFF..................................................................... 20-621
H-16 Machine deviates in one direction ...................................................................................................... 20-622
H-17 Machine deviates largely at start........................................................................................................ 20-624
H-18 Machine deviates largely during compound operation ....................................................................... 20-625
H-19 Travel speed or power is low.............................................................................................................. 20-625
H-20 Machine does not travel (only one track) ........................................................................................... 20-626
H-21 Travel speed does not change ........................................................................................................... 20-627
H-22 Upper structure does not swing ......................................................................................................... 20-628
H-23 Swing speed or acceleration is low .................................................................................................... 20-629
H-24 Swing speed or acceleration is low during compound operation of swing and work equipment........ 20-630
H-25 Upper structure overruns excessively when it stops swinging ........................................................... 20-632
H-26 Large shock is made when upper structure stops swinging............................................................... 20-633
H-27 Large abnormal sound is made when upper structure stops swinging .............................................. 20-634
H-28 Hydraulic drift of swing is large .......................................................................................................... 20-635
PC750, 800-7 20-601

(1)
BEFORE TROUBLESHOOTING FOR HYDRAULIC
TROUBLESHOOTING AND MECHANICAL SYSTEMS (H MODE)
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND

MECHANICAL SYSTEMS (H MODE)
20-602 PC750, 800-7

(1)
1. Combination and operation of hydraulic 2. Finding cause of trouble that "work equip-
pumps ment speed is low and machine deviates to
• For the work equipment, travel, and swing left"
circuits, 2 tandem pumps (4 pump units) of • The possible causes of this trouble are as
the No. 1 pump (HPV95+95) and the No. 2 follows:
pump (HPV95+95) are used. 1) The main relief valve of the left 5-spool
• The oil from the No. 1 front pump and that valve is defective.
from the No. 2 front pump merge together 2) The jet sensor of the left 5-spool valve is
and flow in the left 5-spool valve. The oil defective.
from the No. 1 rear pump and that from the 3) The CO-NC valve of the No. 1 front
No. 2 rear pump merge together and flow in pump is defective.
the right 4-spool valve. 4) The servo valve of the No. 1 front pump
• The TVC valve installed on the No. 1 rear is defective.
pump carries out the TVC control of the No. 5) The No. 1 front pump is defective.
1 pump and No. 2 pump similarly. 6) The servo valve of the No. 2 front pump
• The CO-NC valve installed on the No. 1 front is defective.
pump and the jet sensor installed to the left 7) The No. 2 front pump is defective.
5-spool valve carry out the CO-NC control of • Whether the main relief valve, jet sensor,
the No. 1 front pump and No. 2 front pump and CO-NC valve are good or not can be
similarly. judged by measuring the relief pressure, dif-
• The CO-NC valve installed on the No. 1 rear ferential pressure, and output pressure re-
pump and the jet sensor installed to the right spectively.
4-spool valve carry out the CO-NC control of • Since the oil from the No. 1 front pump and
the No. 1 rear pump and No. 2 rear pump that from the No. 2 front pump merge togeth-
similarly. er as explained in 1 above, exchange the
outlet hoses of the No. 2 front and rear
pumps and check the phenomenon of the
machine to find out a defective system in the
servo valves and pump units of the No. 1 and
No. 2 front pumps.
1) If the machine still deviates to the left (If
deviation does not change), the No. 1
front pump system is defective.
2) If the machine deviates to the right (If
deviation changes), the No. 2 front
pump system is defective.
3) If the travel speed lowers, the jet sensor
or the CO-NC valve is defective (when
the right and left relief pressures are
normal).
• To judge the condition of the servo valve and
pump unit, remove the servo valve and test it
or measure the stroke of the servo piston.
a Actually, judge the condition according "4.
Judgment matrix for trouble that work equip-
ment speed is low and machine deviates".
PC750, 800-7 20-603

(1)
3. Finding cause of trouble that "work equip- 4. Judgment matrix for trouble that work equip-
ment speed is low and machine deviates to ment speed is low and machine deviates (on
right" the next page)
• The possible causes of this trouble are as a Carry out diagnosis in order from the top line
follows: and judge the factor having the most black
1) The main relief valve of the right 4-spool points (q) to be the cause of the trouble.
valve is defective. 1) To judge the servo valve, remove it and test
2) The jet sensor of the right 4-spool valve it or measure the stroke of the servo piston.
is defective. a Perform the test on the servo piston unit
3) The CO-NC valve of the No. 1 rear in the specified maintenance shop.
pump is defective. 2) If the speed lowers extremely and the pump
4) The servo valve of the No. 1 rear pump seems to be abnormal, check the line filter
is defective. too.
5) The No. 1 rear pump is defective. 3) If the speed lowers little but cannot be set to
6) The servo valve of the No. 2 rear pump the normal level by adjusting each device,
is defective. check the line filter too.
7) The No. 2 rear pump is defective. 4) To check the operation of the servo piston,
• Whether the main relief valve, jet sensor, remove the caps from both sides of it and
and CO-NC valve are good or not can be move the servo piston with the hand.
judged by measuring the relief pressure, dif-
ferential pressure, and output pressure re-
spectively.
• Since the oil from the No. 1 rear pump and
that from the No. 2 rear pump merge togeth-
er as explained in 1 above, exchange the
outlet hoses of the No. 2 front and rear
pumps and check the phenomenon of the
machine to find out a defective system in the
servo valves and pump units of the No. 1 and
No. 2 rear pumps.
1) If the machine still deviates to the left (If
deviation does not change), the No. 1
rear pump system is defective.
2) If the machine deviates to the right (If
deviation changes), the No. 2 rear pump
system is defective.
3) If the travel speed lowers, the jet sensor
or the CO-NC valve is defective (when
the right and left relief pressures are
normal).
• To judge the condition of the servo valve and
pump unit, remove the servo valve and test it
or measure the stroke of the servo piston.
a Actually, judge the condition according "4.
Judgment matrix for trouble that work equip-
ment speed is low and machine deviates".
20-604 PC750, 800-7

(1)
Causes
Left Right
No. 1 pump No. 2 pump 5-spool 4-spool
valve valve
Front Rear
Front pump Rear pump
pump pump
Main relief valve defective
Main relief valve defective

CO-NC valve defective
CO-NC valve defective

Servo valve defective
Jet sensor defective
Jet sensor defective

Pump unit defective
Pump unit defective
Pump unit defective
Pump unit defective
Right travel motor

Left travel motor
Remedy A: Adjust
Remedy X: Repair or replace
Remedy
A A A A A A
No.
X X X X X X X X X X X X X X X X
Diagnosis
Machine "deviates to left" and work equipment speed
1
and swing speed are low.
q q q q q q q
Machine "deviates to left" and single swing speed is
2
particularly low.
q q q q q q
Machine "deviates to left" and single swing speed is
3
normal.
q
4 Travel relief pressure of front pump circuit is low. q
Machine "deviates to left"
Machine "deviates to left"

5
(Deviation does not change).
q q q
When result of 4 is nor-
mal, exchange front and Machine "deviates to right"
6
rear outlet hoses of No. 2 (Deviation changes).
q q
pump. Speed of both travel motors
7
is low.
q q
When phenomenon of 5 occurs, servo valve of No. 1
8
front pump is normal.
q
9
front pump is normal.
q
When phenomenon of 7 occurs, jet sensor differential
10
pressure of left 5-spool valve is abnormal.
q
When result of 10 is normal, No. 1 front NC valve output
11
pressure is abnormal.
q
Machine "deviates to right" and work equipment speed
12
is low.
q q q q q q q
Machine "deviates to right" and bucket dump speed is
13
particularly low.
q q q q q q
Machine "deviates to right" and bucket dump speed is
14
normal.
q
15 Travel relief pressure of rear pump circuit is low. q
Machine "deviates to right"
Machine "deviates to right"

16
(Deviation does not change).
q q q
When result of 15 is nor-
mal, exchange front and Machine "deviates to left"
17
rear outlet hoses of No. 2 (Deviation changes).
q q
pump. Speed of both travel motors
18
is low.
q
19
rear pump is normal.
q
20
rear pump is normal.
q
When phenomenon of 18 occurs, jet sensor differential
21
pressure of right 4-spool valve is abnormal.
q
When result of 18 is normal, No. 1 front NC valve output
22
pressure is abnormal.
q
PC750, 800-7 20-605

(1)
How to exchange outlet hoses of No. 2 pump and hydraulic circuit diagram after they are exchanged
20-606 PC750, 800-7

(1)
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE

a Tables and related circuit diagrams concerning troubleshooting contains the following information. Please
understand the contents sufficiently before carrying out troubleshooting.
Failure
Phenomena on machine
Phenomenon
Related
Information concerning to failure or troubleshooting.
Information
1
Presumed cause and
2
Possible causes of
failure <Contents>
(The sequence number is • Standard values for judgement of possible causes.
only for reference and • Remarks for judgement
does not state priority.)
3
PC750, 800-7 20-607

(1)
TROUBLESHOOTING H-1
H-1 Speed or power of all work equipment, travel, and swing is low
Failure
• Speed or power of all work equipment, travel, and swing is low
information
• Measure the speed of the work equipment, travel, and swing speed and check that all of them are slow
(or their power is low).
• Check that abnormal sound is not heard from around the pump.
Relative
(If abnormal sound is heard, carry out the related troubleshooting.)
information
• Check that the machine does not deviate.
(If the machine deviates, carry out the related troubleshooting.)
• Carry out all the troubleshooting in working mode A.

a Run the engine at high idling during troubleshooting.
Heavy lift switch and right work
Engine speed
equipment control lever
1 Engine unit defective
Heavy lift switch OFF +
Above 1,700 rpm
Boom RAISE relief
Heavy lift switch ON + Boom RAISE relief Above 1,700 rpm
PTO defective internally a Keep the engine stopped for the preparations and troubleshooting.
2 (Control pump drive Disconnect the control pump outlet hose and rotate the crankshaft. If oil flows out of
system) the pump outlet, PTO is normal.
Control pump defective Control pump may be defective internally. Check inside of pilot filter for metal dust,
3
internally etc.
a Keep the engine stopped for the preparations, and run it at high idling during
troubleshooting.
Control levers Control relief pressure
Wrong adjustment or 3.33
+0.49
MPa
0
4 malfunction of control All levers in neutral
Presumed cause and
+5
relief valve {34 0 kg/cm2}
If the oil pressure is still abnormal after adjustment, check cause 5. If cause 5 is not
detected, the control relief valve operation may be defective. Check the control relief
valve directly.
a Stop the engine and block (1) – (9) in Fig. 1 in order. Run the engine at high idling
and check.
Leakage in control Control levers Control relief pressure
5
system devices +0.49
3.33 0 MPa
All levers in neutral +5
{34 0 kg/cm2}
troubleshooting.

Main relief pressure
+1.0
Wrong adjustment or Heavy lift switch OFF + 31.4 –2.0 MPa
6 malfunction of main relief Boom RAISE relief +10
{320 –20 kg/cm2}
valve
+1.0
Heavy lift switch ON + 33.8 –2.0 MPa
Boom RAISE relief +10
{345 –20 kg/cm2}
If the oil pressure is still abnormal after adjustment, the main relief valve (on the low-
pressure set side and high-pressure set side) may be defective. Check the main
relief valve directly.
20-608 PC750, 800-7

(1)
TROUBLESHOOTING H-1

troubleshooting (Start troubleshooting after checking that causes 4 and 6 are not
detected).
TVC valve output pressure
Min. 1.76 MPa

Wrong adjustment or All levers in neutral
Presumed cause and
7 {Min. 18 kg/cm2}
malfunction of TVC valve
Heavy lift switch OFF + 1.18 ± 0.2 MPa
Boom RAISE relief {12 ± 2 kg/cm2}
1.14 ± 0.2 MPa
Heavy lift switch ON + Boom RAISE relief
{11.6 ± 2 kg/cm2}
If the oil pressure is still abnormal after adjustment, the TVC valve may be defective.
Check the TVC valve directly.
troubleshooting.
Malfunction of CO Working mode Solenoid valve outlet pressure
8
cancel solenoid valve Min. 2.74 MPa
A-mode
{Min. 28 kg/cm2}
E-mode 0 MPa {0 kg/cm2}
Fig. 1: Control system devices
PC750, 800-7 20-609

(1)
TROUBLESHOOTING H-2
H-2 Engine speed lowers remarkably or engine stalls
Failure
• Engine speed lowers remarkably or engine stalls
Phenomenon
Related
Information

a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idling.
Heavy lift switch
TVC valve output pressure
R.H. work equipment control lever
Min. 1.76 MPa
All control levers in neutral
Defective adjustment or {Min. 18 kg/cm2}
1
malfunction of TVC valve Heavy lift switch OFF + 1.18 ± 0.2 MPa
Boom relieved in RAISE position {12 ± 2 kg/cm2}
Heavy lift switch ON + 1.14 ± 0.2 MPa

Presumed cause and
Boom relieved in RAISE position {11.6 ± 2 kg/cm2}

If the oil pressure cannot be set normally by adjustment, the TVC valve may have a
malfunction. Check the TVC valve directly.
high idling. (Check cause 1 and confirm that the result is normal before
troubleshooting.)
Heavy lift switch
CO • NC valve output pressure
Defective adjustment or R.H. work equipment control lever
2 malfunction of CO • NC Heavy lift switch OFF + 1.18 ± 0.2 MPa
valve Boom relieved in RAISE position {12 ± 2 kg/cm2}
Heavy lift switch ON + 1.14 ± 0.2 MPa
Boom relieved in RAISE position {11.6 ± 2 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the CO • NC valve may have
a malfunction. Check the CO • NC valve directly.
If the results of check of causes 1 and 2 are normal, the engine may be defective.
3 Defective engine
Check the engine
20-610 PC750, 800-7

(1)
TROUBLESHOOTING H-3
H-3 All work equipment, travel, and swing systems do not work
Failure
• All work equipment, travel, and swing systems do not work
information
Relative
information

1 (Main pump drive Disconnect the main pump oil pressure pickup coupler and rotate the crankshaft. If
system) oil flows out of the pump outlet, PTO is normal.
2 (Control pump drive Disconnect the control pump outlet hose and rotate the crankshaft. If oil flows out of
system) the pump outlet, PTO is normal.
Control pump defective Control pump may be defective internally. Check inside of pilot filter for metal dust,
3
internally etc.
troubleshooting.
Control levers Control relief pressure

Presumed cause and
Wrong adjustment or 3.33

+0.49
MPa
0
4 malfunction of control All levers in neutral +5
relief valve {34 0 kg/cm2}
If the oil pressure is still abnormal after adjustment, check cause 5. If cause 5 is not
detected, the control relief valve operation may be defective. Check the control relief
valve directly.
a Stop the engine and block (1) – (9) in Fig. 1 in order. Run the engine at high idling
and check.
Leakage in control Control levers Control relief pressure
5
system devices +0.49
3.33 0 MPa
All levers in neutral +5
{34 0 kg/cm2}
troubleshooting.
Malfunction of PPC lock Safety lock lever Solenoid valve outlet pressure
6
solenoid valve Min. 2.74 MPa
FREE
{28 kg/cm2}
LOCK 0 MPa {0 kg/cm2}
PC750, 800-7 20-611

(1)
TROUBLESHOOTING H-3, H-4
Fig. 1: Control system devices
H-4 Abnormal sound is heard from around pump
Failure
• Abnormal sound is heard from around pump
Phenomenon
Related
Information

Presumed cause and standard
1 Low hydraulic oil level Since the hydraulic oil level may be low, check it directly.
Since a piping clamp between the hydraulic tank and hydraulic pump may be loos-
value in normalcy
2 Loosened piping clamp

ened, check it directly.
Clogged hydraulic tank
3 Since the hydraulic tank strainer may be clogged, check it directly.
strainer
Internal defect of hydrau-
4 Since the hydraulic pump may have a defect in it, check it directly.
lic pump
If a cause cannot be found by troubleshooting, operate the machine as it is for a
5 Observation of condition
while and observe the condition for change.
20-612 PC750, 800-7

(1)
TROUBLESHOOTING H-5
H-5 Boom speed or power is low
Failure (1) The boom speed or power is low in the normal

• Boom speed or power is low
information mode.
• The normal mode is the state that the heavy lift switch, swing priority switch, and machine push-up
switch are turned OFF.
Relative • Check that the other work equipment, travel, and swing are normal. (If any of them is abnormal, carry
information out troubleshooting related to it.)
• Check that the machine does not deviate. (If it deviates, carry out troubleshooting related to deviation.)
• When carrying out the following troubleshooting, set the working mode in the A-mode.

troubleshooting.
Malfunction of right PPC
1 Right work equipment control lever PPC valve output pressure
valve (Boom circuit)
Min. 2.74 MPa
Boom RAISE/LOWER stroke end
{Min. 28 kg/cm2}
troubleshooting.
Swing priority switch and
Solenoid valve outlet pressure
Malfunction of swing right work equipment control lever
2
priority solenoid valve Swing priority switch OFF +
Presumed cause and
0 MPa {0 kg/cm2}
Lever in neutral
Swing priority switch ON + Min. 2.74 MPa
Boom RAISE operation {Min. 28 kg/cm2}
Malfunction of boom
3 The spool of the boom control valve (Lo, Hi) may malfunction. Check it directly.
control valve (spool)
The safety-suction valve of the boom control valve (Lo) may malfunction. Check it
Malfunction of boom directly. (When checking the safety-suction valve by exchanging it with a valve of
4 control valve another work equipment circuit, stop the hose of the machine push-up solenoid
(Safety-suction valve) securely. After finishing check, be sure to return the safety-suction valve since its set
pressure and structure are different from others.)
Boom control valve
The control valve unit of the boom control valve (Lo, Hi) may be defective. Check it
5 (control valve unit)
directly.
defective
Boom cylinder seal troubleshooting.
6
defective Right work equipment control lever Leakage from cylinder
Boom RAISE relief Max. 20 cc/min
PC750, 800-7 20-613

(1)
TROUBLESHOOTING H-5
Failure (2) The boom raise speed or power is low in the heavy
information lift mode.
• The heavy lift mode is the state that the heavy lift switch is turned ON.
• Check that the other work equipment, travel, and swing are normal. (If any of them is abnormal, carry
Relative
out troubleshooting related to it.)
information

troubleshooting.
Malfunction of CO Right work equipment control lever Solenoid valve outlet pressure
1
cancel solenoid valve Neutral 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Single boom RAISE operation
{Min. 28 kg/cm2}
Presumed cause and
troubleshooting.
Malfunction of 2-stage Right work equipment control lever Solenoid valve outlet pressure
2
relief solenoid valve Neutral 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Single boom RAISE operation
{Min. 28 kg/cm2}
troubleshooting.
Right work equipment control lever Main relief pressure
Wrong adjustment or +1.0
3 malfunction of main relief 33.8 –2.0 MPa
valve Single boom RAISE operation +10
{345 –20 kg/cm2}
If the main relief valve is still abnormal after adjustment, its operation (on the high
pressure set side) may be defective. Check it directly.
Failure (3) The boom lower speed or power is low in the

information machine push-up mode.
• The heavy lift mode is the state that the machine push-up switch is turned ON.
• Check that the other work equipment, travel, and swing are normal. (If any of them is abnormal, carry
Relative
out troubleshooting related to it.)
information

Presumed cause and
troubleshooting.
Malfunction of machine Machine push-up switch Solenoid valve outlet pressure
1
push-up solenoid valve Min. 2.74 MPa
OFF
{Min. 28 kg/cm2}
ON 0 MPa {0 kg/cm2}
Malfunction of boom
The safety-suction valve of the boom control valve (Lo) (on the high pressure set side
2 control valve
on the head side) may malfunction. Check it directly.
(Safety-suction valve)
20-614 PC750, 800-7

(1)
TROUBLESHOOTING H-6
H-6 Speed or power of arm is low
Failure
• Speed or power of arm is low
Phenomenon
• Check that the speeds of the other work equipment, travel, and swing are normal.
(If they are abnormal, carry out the related troubleshooting.)
Related
Information

high idling.
Malfunction of left PPC
1 L.H. work equipment control lever PPC valve output pressure
valve (arm circuit)
Arm IN, OUT Min. 2.74 MPa
Full stroke {Min. 28 kg/cm2}

Presumed cause and
Malfunction of arm Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it
2
control valve (spool) directly.
The safety-suction valve of the arm control valve (Lo, Hi) may malfunction. Check it
Malfunction of arm
directly. (After checking the safety-suction valve by exchanging it with a valve of
3 control valve
another work equipment circuit, be sure to return it since its set pressure is different
(safety & suction valve)
from others.)
Defective arm control Since the body of the arm control valve (Lo, Hi) may have a malfunction, check it
4
valve (body) directly.
Defective seal of arm high idling.
5
cylinder L.H. work equipment control lever Leakage from cylinder
Relieved in arm IN position Max. 20 cc/min
PC750, 800-7 20-615

(1)
TROUBLESHOOTING H-7
H-7 Speed or power of bucket is low
Failure
• Speed or power of bucket is low
Phenomenon
• Check that the speeds of the other work equipment, travel, and swing are normal.
Related
Information

high idling.
Malfunction of right PPC R.H. work equipment control lever
1 PPC valve output pressure
valve (bucket circuit) (bucket)
Bucket CURL, DUMP Min. 2.74 MPa
Presumed cause and
Malfunction of bucket Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it
2
Since the safety & suction valve of the bucket control valve (Lo, Hi) may have a mal-
Malfunction of bucket function, check it directly. (The safety & suction valve may be checked by replacing it
3 control valve with one of another work equipment circuit. After checking, however, be sure to
(safety & suction valve) return the safety & suction valve since its set pressure and structure are different
from the others.)
Defective bucket control Since the body of the bucket control valve (Lo, Hi) may have a malfunction, check it
4
valve (body) directly.
high idling.
Defective seal of bucket
5 R.H. work equipment control lever
cylinder Leakage from cylinder
(bucket)
Relieved in bucket CURL position Max. 20 cc/min
20-616 PC750, 800-7

(1)
TROUBLESHOOTING H-8, H-9, H-10
H-8 Boom does not move
Failure
• Boom does not move
Phenomenon
• Check that operations of the other work equipment, travel, and swing are normal.
Related
Information

high idling.
value in normalcy

1 valve R.H. work equipment control lever PPC valve output pressure
(boom circuit) Boom RAISE, LOWER Min. 2.74 MPa
Malfunction of boom Since the spool of the boom control valve (Lo, Hi) may have a malfunction, check it
2
H-9 Arm does not move
Failure
• Arm does not move
Phenomenon
Related
Information

high idling.
value in normalcy

1 L.H. work equipment control lever PPC valve output pressure
valve (arm circuit)
Arm IN, OUT Min. 2.74 MPa
Malfunction of arm Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it
2
H-10 Bucket does not move
Failure
• Bucket does not move
Phenomenon
Related
Information

high idling.
value in normalcy

1 R.H. work equipment control lever PPC valve output pressure
valve (bucket circuit)
Bucket CURL, DUMP Min. 2.74 MPa
Malfunction of bucket Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it
2
PC750, 800-7 20-617

(1)
TROUBLESHOOTING H-11
H-11 Hydraulic drift of work equipment is large
Failure
• Hydraulic drift of work equipment is large (1) Hydraulic drift of boom is large
Phenomenon
Related
Information

Defective seal of boom

1 Since the spool of the boom control valve (Lo) may have a malfunction, check it directly.
Since the safety & suction valve (bottom side) of the boom control valve (Lo) may have
value in normalcy
Malfunction of boom con- a malfunction, check it directly. (The safety & suction valve may be checked by replac-
2 trol valve (safety & suc- ing it with one of another work equipment circuit. After checking, however, be sure to
tion valve) return the safety & suction valve since its set pressure and structure are different from
the others.)
a Prepare with the engine stopped, then carry out troubleshooting with the engine at high
Defective seal of boom idling.
3
cylinder R.H. work equipment control lever Leakage from cylinder
Relieved in boom RAISE position Max. 20 cc/min
Failure
• Hydraulic drift of work equipment is large (2) Hydraulic drift of arm is large
Phenomenon
Related
Information

Defective seal of arm Since the spool of the arm control valve (Lo) may have a malfunction, check it
1
Since the safety & suction valve (head side) of the arm control valve (Lo) may have a
value in normalcy
Malfunction of arm malfunction, check it directly. (The safety & suction valve may be checked by replac-
2 control valve ing it with one of another work equipment circuit. After checking, however, be sure to
(safety & suction valve) return the safety & suction valve since its set pressure and structure are different
from the others.)
Defective seal of arm high idling.
3
cylinder L.H. work equipment control lever Leakage from cylinder
Relieved in arm IN position Max. 20 cc/min
20-618 PC750, 800-7

(1)
Failure
• Hydraulic drift of work equipment is large (3) Hydraulic drift of bucket is large
Phenomenon
Related
Information

Defective seal of bucket Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it
1
Since the safety & suction valve (bottom side) of the bucket control valve (Lo, Hi)
value in normalcy
Malfunction of bucket may have a malfunction, check it directly. (The safety & suction valve may be
2 control valve checked by replacing it with one of another work equipment circuit. After checking,
(safety & suction valve) however, be sure to return the safety & suction valve since its set pressure and struc-
ture are different from the others.)
Defective seal of bucket high idling.
3
cylinder R.H. work equipment control lever Leakage from cylinder
Relieved in bucket CURL position Max. 20 cc/min
PC750, 800-7 20-619

(1)
H-12 Time lag of work equipment is large
Failure
• Time lag of work equipment is large (1) Time lag of boom is large
Phenomenon
Related
Information
Presumed Since the safety & suction valve (head side) of the boom control valve (Lo)
cause and may have a malfunction, check it directly. (When checking by replacing the
Malfunction of boom
standard value safety & suction valve with one of another work equipment circuit, stop the oil
1 control valve (safety
in normalcy in the machine pushup solenoid hose securely. After checking, be sure to
& suction valve)
return the safety & suction valve since its set pressure and structure are differ-
ent from the others.)
Failure
• Time lag of work equipment is large (2) Time lag of arm is large
Phenomenon
Related
Information

Presumed Since the safety & suction valve (bottom side) of the arm control valve (Lo, Hi)
cause and Malfunction of arm may have a malfunction, check it directly. (The safety & suction valve may be
standard value 1 control valve (safety checked by replacing it with one of another work equipment circuit. After
in normalcy & suction valve) checking, however, be sure to return the safety & suction valve since its set
pressure and structure are different from the others.)
Failure
• Time lag of work equipment is large (3) Time lag of bucket is large
Phenomenon
Related
Information

Presumed Since the safety & suction valve (bottom side) of the bucket control valve (Lo,
cause and Malfunction of bucket Hi) may have a malfunction, check it directly. (The safety & suction valve may
standard value 1 control valve (safety be checked by replacing it with one of another work equipment circuit. After
in normalcy & suction valve) checking, however, be sure to return the safety & suction valve since its set
pressure and structure are different from the others.)
20-620 PC750, 800-7

(1)
TROUBLESHOOTING H-13, H-14, H-15
H-13 Heavy lift function does not operate or stop
Failure
• Heavy lift function does not operate or stop
Phenomenon
Related
Information

cause and
standard value 1 Check by (2) in "H-5 Boom speed or power is low".
in normalcy
H-14 Machine push-up function does not operate or stop
Failure
• Machine push-up function does not operate or stop
Phenomenon
Related
Information

cause and
standard value 1 Check by (3) in "H-5 Boom speed or power is low".
in normalcy
H-15 Boom shockless function cannot be turned ON or OFF
Failure
• Boom shockless function cannot be turned ON or OFF
Phenomenon
Related
Information

a Prepare with starting switch OFF, then carry out troubleshooting with the
Presumed Malfunction of boom starting switch ON.
cause and 1 shockless solenoid Remove the solenoid valve from the valve assembly and connect the connec-
standard value valve tor and operate the boom shockless control switch. If the spool moves at this
in normalcy time, the solenoid valve is normal.
Malfunction of boom
2 Since the boom shockless valve may have a malfunction, check it directly.
shockless valve
PC750, 800-7 20-621

(1)
H-16 Machine deviates in one direction
Failure (1) Machine deviates in the same direction, regardless

• Machine deviates in one direction
Phenomenon of its travel direction
Related • Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.)
Information • Carry out all the troubleshooting in working mode A.

Troubleshooting with Carry out troubleshooting by using the judgment matrix in BEFORE TROUBLE-
1
judgment matrix SHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS. (H mode)
Wrong adjustment of
2 See TESTING AND ADJUSTING, Testing and adjusting travel deviation.
main pump
Presumed cause and standard value in normalcy
high idling.
Malfunction of travel PPC
3 Travel lever PPC valve output pressure
valve
FORWARD, REVERSE 2.74 MPa
Full stroke {28 kg/cm2}
Malfunction of travel
4 Since the spool of the travel control valve may have a malfunction, check it directly.
Defective travel control
5 Since the body of the travel control valve may have a malfunction, check it directly.
valve (body)
high idling.
Defective seal of center Travel lever Leakage from swivel joint
6
swivel joint
Relieved on one side Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 1.
high idling.
7 Leakage in travel motor
Travel lever Leakage from travel motor
Relieved on one side Max. 40 l/min
8 Defective travel motor Since the travel motor may be defective, check it directly.
Internal defect of final Since the final drive may have a defect in it, check it directly. (The defect can be
9
drive judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.)
20-622 PC750, 800-7

(1)
Failure (2) Machine deviates in different directions, depending

• Machine deviates in one direction
Phenomenon on its travel direction
Related • Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.)
Information • Carry out all the troubleshooting in working mode A.

high idling.
PPC valve
FORWARD, REVERSE 2.74 MPa
Full stroke {28 kg/cm2}
Presumed cause and
high idling.
Defective seal of center Travel lever Leakage from swivel joint
3
swivel joint
Relieved on one side Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 1.
high idling.
Low set pressure of Travel lever Travel relief pressure
4
travel motor safety valve +1.0
34.3 –2.0 MPa
Relieved on one side +10
{350 –20 kg/cm2}
Fig. 1 Defective seals in center swivel joint and travel deviation directions
PC750, 800-7 20-623

(1)
H-17 Machine deviates largely at start
Failure (1) Machine deviates only when started with travel lever
• Machine deviates largely at start
Phenomenon at full stroke
• Check that the machine does not deviate during constant-speed travel.
Related
(If the machine deviates even during constant-speed travel, carry out the related troubleshooting.)
Information

Malfunction of main Since the servo-valve of main pumps (No. 1 & No. 2) may have a malfunction, check
1
pump servo-valve it directly. (Test the servo-valve unit or measure its stroke.)
value in normalcy
Defective seal of center troubleshooting.
3
swivel joint Travel lever Leakage from swivel joint
Either side relief Max. 100 cc/min
Internal defect of travel
4 Since the travel motor may have a defect in it, check it directly.
motor (body)
Failure (2) Machine deviates when started, regardless of travel

• Machine deviates largely at start
Phenomenon lever stroke
• Check that the machine does not deviate during constant-speed travel.
Related
(If the machine deviates even during constant-speed travel, carry out the related troubleshooting.)
Information

high idling. (Check cause 3 and confirm that the result is normal before
troubleshooting.)
Travel lever CO • NC valve output pressure
Defective adjustment or
Max. 0.55 MPa
1 malfunction of CO • NC Neutral
{Max. 5.5 kg/cm2}
valve
Min. 1.67 MPa

Full stroke on one side (Idle travel)
Presumed cause and
{Min. 17 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the CO • NC valve may have
a malfunction or may be adjusted defectively. Check the CO • NC valve directly.
Malfunction of main Since the servo-valve of main pump may have a malfunction, check it directly.
2
pump servo-valve (Test the servo-valve unit or measure its stroke.)
high idling.
Travel lever Differential pressure of jet sensor
Min. 1.14 MPa
Defective adjustment or Neutral
3 {Min. 11.6 kg/cm2}
malfunction of jet sensor
Max. 0.15 MPa
Full stroke on one side (Idle travel)
{Max. 1.5 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the relief valve may have a
malfunction or the orifice may be defective. Check the relief valve and orifice directly.
20-624 PC750, 800-7

(1)
TROUBLESHOOTING H-18, H-19
H-18 Machine deviates largely during compound operation
Failure
• Machine deviates largely during compound operation
Phenomenon
• Check that the machine does not deviate when the work equipment is not operated.
Related
(If the machine deviates under that condition, carry out the related troubleshooting.)
Information

Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idling.
value in normalcy
Malfunction of travel Control levers Solenoid valve outlet pressure

1
junction solenoid valve All levers in neutral 0 MPa {0 kg/cm2}
Operation of work equipment or swing
Min. 2.74 MPa {Min. 28 kg/cm2}
+ Travel
Malfunction of travel Since the travel junction valve of the travel control valve may have a malfunction,
2
junction valve check it directly.
H-19 Travel speed or power is low
Failure
• Travel speed or power is low
Phenomenon
Related
Information

troubleshooting.
valve
Min. 2.74 MPa
Forward/Reverse stroke end
{Min. 28 kg/cm2}
troubleshooting.
Malfunction of CO Travel lever Solenoid valve outlet pressure
2
cancel solenoid valve Neutral 0 MPa {0 kg/cm2}

Presumed cause and
Min. 2.74 MPa

Operated
{Min. 28 kg/cm2}
troubleshooting.
Malfunction of 2-stage Travel lever Solenoid valve outlet pressure
3
relief solenoid valve Neutral 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Operated
{Min. 28 kg/cm2}
troubleshooting.
Travel lever Travel relief pressure
Wrong adjustment or
+1.0
4 malfunction of main relief 34.3 –2.0 MPa
valve Either side relieved +10
{350 –20 kg/cm2}
If the main relief valve is still abnormal after adjustment, its operation (on the high
pressure set side) may be defective. Check it directly.
PC750, 800-7 20-625

(1)
H-20 Machine does not travel (only one track)
Failure
• Machine does not travel (only one track) (1) Machine does not travel in either direction.
Phenomenon
Related
Information

Presumed cause and
1 Since the parking brake of the travel motor may have a malfunction, check it directly.
motor (parking brake)
Internal defect of travel
2 Since the travel motor may have a defect in it, check it directly.
motor (body)
Internal defect of final Since the final drive may have a defect in it, check it directly. (The defect can be
3
drive judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.)
Failure
• Machine does not travel (only one track) (2) Machine does not travel forward or in reverse
Phenomenon
Related
Information

high idling.
1 Travel levers PPC valve output pressure
valve
FORWARD, REVERSE Min. 2.74 MPa
Presumed cause and
Defective travel control Since the suction valve of the travel control valve may have a malfunction, check it
3
valve (suction valve) directly. (The suction valve can be checked by replacing it with normal one.)
high idling.
Malfunction of travel Travel levers Travel relief pressure
4
motor (safety valve) +1.0
Relieved on one side 34.3 –2.0 MPa
(Direction in which machine does not travel) +10
{350 –20 kg/cm2}
Since the counterbalance valve of the travel motor may have a malfunction, check it
5 motor
directly.
(counterbalance valve)
20-626 PC750, 800-7

(1)
H-21 Travel speed does not change
Failure
• Travel speed does not change
Phenomenon
• Check that the Lo and Hi travel speeds are normal.
Related • The travel speed selection system has the automatic speed changing function. If the oil pressure rises
Information above 22.6 MPa {230 kg/cm2} during travel, the travel speed is changed to Lo even while the machine
is traveling at Hi (Hi is still displayed on the monitor panel).

Presumed cause and
high idling.
Malfunction of travel Travel speed selection switch Solenoid valve outlet pressure
1
speed solenoid valve Lo 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Hi
{Min.28 kg/cm2}
Malfunction of travel Since the servo mechanism of the travel motor may have a malfunction, check it
2
motor (servo mechanism) directly.
PC750, 800-7 20-627

(1)
H-22 Upper structure does not swing
Failure
• Upper structure does not swing (1) The upper structure swings in neither direction.
Phenomenon
• Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out
Related troubleshooting related to it.)
Information • When carrying out the following troubleshooting, set the swing lock switch in OFF and the working
mode in the A-mode.

troubleshooting.
Malfunction of swing Left work equipment control lever Solenoid valve outlet pressure
1 holding brake solenoid
valve Neutral (After 10 seconds or more) 0 MPa {0 kg/cm2}
Operated to swing Min. 2.74 MPa
(in either direction) {Min.28 kg/cm2}
Presumed cause and
Malfunction of swing
2 The parking brake of the swing motor may malfunction. Check it directly.
troubleshooting.
Left work equipment control lever Swing relief pressure
3 malfunction of swing Swing relief 28.4 –0.5 MPa
motor (safety valve) (in either direction) +25
{290 –5 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction.
check the safety valve directly.
Swing motor (motor unit)
4 The motor unit of the swing motor may have a defect in it. Check it directly.
defective internally
Swing machinery Swing machinery may have a defect in it. Check it directly. (The swing machinery can
5
defective internally be checked by abnormal sound, abnormal heating, metal dust in the drained oil, etc.)
Failure
• Upper structure does not swing (2) The upper structure does not swing in only 1 direction.
Phenomenon
Information • When carrying out the following troubleshooting, set the swing lock switch in OFF and the working
mode in the A-mode.

troubleshooting.
1 Left work equipment control lever PPC valve output pressure
valve (swing circuit)
Min. 2.74 MPa

Swing RIGHT/LEFT stroke end
Presumed cause and
{Min.28 kg/cm2}
2 The spool of the swing control valve may malfunction. Check it directly.
Malfunction of swing The suction valve of the swing control valve may malfunction. Check it directly.
3 control valve (The suction valves of the right and left swing control valves can be checked by
(suction valve) exchanging them with each other and seeing the change of the phenomenon.)
The suction valve of the swing motor may malfunction. Check it directly.
4 (The suction valves of the right and left swing motors can be checked by exchanging
motor (suction valve)
them with each other and seeing the change of the phenomenon.)
The check valve of the swing motor may malfunction. Check it directly.
5 (The check valves of the right and left swing motors can be checked by exchanging
motor (check valve)
20-628 PC750, 800-7

(1)
H-23 Swing speed or acceleration is low
Failure (1) The swing speed or acceleration is low in both direc-

• Swing speed or acceleration is low
Phenomenon tions.
Information • When carrying out the following troubleshooting, set the working mode in the A-mode and turn the
swing lock switch OFF.

troubleshooting.
1 Leakage in swing motor
Left work equipment control lever Leakage from swing motor
Swing relief (in either direction) Max. 10 l/min
Presumed cause and
troubleshooting.
{290 –5 kg/cm2}
Swing machinery may have a defect in it. Check it directly. (The swing machinery
Swing machinery
5 can be checked by abnormal sound, abnormal heating, metal dust in the drained oil,
etc.)
Failure (2) The swing speed or acceleration is low in only 1

• Swing speed or acceleration is low
Phenomenon direction.

troubleshooting.
Min. 2.74 MPa

Presumed cause and
{Min. 28 kg/cm2}
Malfunction of swing The suction valve of the swing control valve may malfunction. Check it directly. (The
3 control valve suction valves of the right and left swing control valves can be checked by exchang-
(suction valve) ing them with each other and seeing the change of the phenomenon.)
motor (check valve)
PC750, 800-7 20-629

(1)
H-24 Swing speed or acceleration is low during compound operation of swing and
work equipment
• Swing speed or acceleration is low during (1) The swing speed or acceleration is low during com-
Failure
compound operation of swing and work pound operation of swing and work equipment with
Phenomenon
equipment the swing priority mode OFF.
Related • When carrying out the following troubleshooting, set the working mode in the A-mode and turn the
Information swing lock switch OFF.

troubleshooting.
1
priority solenoid valve Swing priority switch OFF + Min. 2.35 MPa
Swing priority switch ON +
0 Pa {0 kg/cm2}
Boom RAISE operation
Presumed cause and
troubleshooting.
2 Right work equipment control lever Swing PPC shuttle valve outlet pressure
PPC shuttle valve
Min. 2.74 MPa
{Min. 28 kg/cm2}
troubleshooting.
Malfunction of swing Swing priority selector valve
3 Right work equipment control lever
priority selector valve outlet pressure (Port A2)
Neutral 0 Pa {0 kg/cm2}
Swing RIGHT/LEFT stroke end Same as main pump pressure
Malfunction of arm
4 control valve The throttle valve of the arm control valve (Lo) may malfunction. Check it directly.
(throttle valve)
Malfunction of bucket
5 control valve The throttle valve of the bucket control valve (Hi) may malfunction. Check it directly.
(throttle valve)
20-630 PC750, 800-7

(1)
• Swing speed or acceleration is low during (2) The swing speed or acceleration is low during com-
Failure
compound operation of swing and work pound operation of swing and work equipment with
Phenomenon
equipment the swing priority mode ON.
• Before carry out the following troubleshooting, check that the swing speed is normal when the swing
Related priority switch is turned OFF.

troubleshooting.
1
priority solenoid valve Swing priority switch OFF + Min. 2.35 MPa
Presumed cause and

Swing priority switch ON +
0 Pa {0 kg/cm2}
Boom RAISE operation
troubleshooting.
Malfunction of swing Swing priority selector valve
2 Right work equipment control lever
priority selector valve outlet pressure (Port A1)
Neutral 0 Pa {0 kg/cm2}
Boom RAISE stroke end 0 Pa {0 kg/cm2}
3 control valve The throttle valve of the swing control valve may malfunction. Check it directly.
(throttle valve)
PC750, 800-7 20-631

(1)
H-25 Upper structure overruns excessively when it stops swinging
Failure • Upper structure overruns excessively when it (1) The upper structure overruns excessively when it
Phenomenon stops swinging stops swinging in both directions.
Related
Information

troubleshooting.

Presumed cause and

{290 –5 kg/cm2}
troubleshooting.
2 Leakage in swing motor
Left work equipment control lever Leakage from swing motor
Swing relief (in either direction) Max. 10 l/min
Failure • Upper structure overruns excessively when it (2) The upper structure overruns excessively when it
Phenomenon stops swinging stops swinging in only 1 direction.
Related
Information

troubleshooting.
Min. 2.74 MPa

Presumed cause and
{Min. 28 kg/cm2}
The suction valve of the swing control valve may malfunction. Check it directly.
Malfunction of swing con-
3 (The suction valves of the right and left swing control valves can be checked by
trol valve (suction valve)
exchanging them with each other and seeing the change of the phenomenon.)
motor (check valve)
20-632 PC750, 800-7

(1)
H-26 Large shock is made when upper structure stops swinging
Failure • Large shock is made when upper structure (1) Large shock is made when the upper structure stops
Phenomenon stops swinging swinging in both directions.

troubleshooting.
Min. 2.74 MPa
Operated to swing (in either direction)
{Min. 28 kg/cm2}
Presumed cause and
troubleshooting.
3 malfunction of swing 28.4 –0.5 MPa
motor (safety valve) Swing relief (in either direction) +25
{290 –5 kg/cm2}
Check the safety valve directly.
Swing machinery
etc.)
Failure • Large shock is made when the upper struc- (2) Large shock is made when the upper structure stops
Phenomenon ture stops swinging. swinging in only 1 direction.

troubleshooting.
Presumed cause and
Malfunction of left PPC Left work equipment control lever PPC valve output pressure
1
valve (swing circuit) Neutral 0 MPa {0 kg/cm2}
Min. 2.74 MPa
{Min. 28 kg/cm2}
PC750, 800-7 20-633

(1)
H-27 Large abnormal sound is made when upper structure stops swinging
Failure • Large abnormal sound is made when upper (1) Large abnormal sound is made when the upper
Phenomenon structure stops swinging structure stops swinging in both directions.
Related
Information

Malfunction of back
1 pressure compensation The back pressure compensation valve may malfunction. Check it directly.
valve
Presumed cause and
troubleshooting.
2 malfunction of swing 28.4 –0.5 MPa
motor (safety valve) Swing relief (in either direction) +25
{290 –5 kg/cm2}
Check the safety valve directly.
Swing machinery
etc.)
Failure • Large abnormal sound is made when upper (2) Large abnormal sound is made when the upper
Phenomenon structure stops swinging structure stops swinging in only 1 direction.
Related
Information

Presumed cause and
Malfunction of swing The suction valve of the swing control valve may malfunction. Check it directly.
1 control valve (The suction valves of the right and left swing control valves can be checked by
(suction valve) exchanging them with each other and seeing the change of the phenomenon.)
20-634 PC750, 800-7

(1)
H-28 Hydraulic drift of swing is large
Failure
• Hydraulic drift of swing is large (1) While the swing holding brake is applied.
Phenomenon
Related
Information

Presumed cause and
troubleshooting.
Min. 2.74 MPa
Operated to swing (in either direction)
{Min. 28 kg/cm2}
Failure
• Hydraulic drift of swing is large (2) While the swing holding brake is released.
Phenomenon
Related
Information


Presumed cause and
2 control valve The suction valve of the swing control valve may malfunction. Check it directly.
(suction valve)
3 The safety valve of the swing motor may malfunction. Check it directly.
motor (safety valve)
4 The suction valve of the swing motor may malfunction. Check it directly.
5 The check valve of the swing motor may malfunction. Check it directly.
motor (check valve)
PC750, 800-7 20-635

(1)
TROUBLESHOOTING OF ENGINE
(S MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-702

METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-703
S-1 Starting performance is poor (starting always takes time).................................................................... 20-706
S-2 Engine does not start ........................................................................................................................... 20-707
S-3 Engine does not pick up smoothly (follow-up is poor) .......................................................................... 20-710
S-4 Engine stops during operations ............................................................................................................ 20- 711
S-5 Engine does not rotate smoothly (hunting)........................................................................................... 20-712
S-6 Engine lacks output (or lacks power) ................................................................................................... 20-713
S-7 Exhaust smoke is black (incomplete combustion)................................................................................ 20-714
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 20-715
S-9 Oil becomes contaminated quickly ....................................................................................................... 20-716
S-10 Fuel consumption is excessive........................................................................................................... 20-717
S-11 Oil is in cooling water (or water spurts back, or water level goes down) ............................................ 20-718
S-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................................. 20-719
S-13 Oil level rises (water, fuel in oil) .......................................................................................................... 20-720
S-14 Water temperature becomes too high (overheating) .......................................................................... 20-721
S-15 Abnormal noise is made..................................................................................................................... 20-722
S-16 Vibration is excessive ......................................................................................................................... 20-723
PC750, 800-7 20-701

(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the
parking brake is securely applied.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious
burns. Always wait for the water temperature to go down before removing the radiator cap.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing a plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various
questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3. Checks before troubleshooting

hurry to disassemble the components 1) Is there any sign of abnormality in the
If components are disassembled immediately machine or engine?
any failure occurs: 2) Always carry out the Checks before starting.
• Parts that have no connection with the failure 3) Carry out other checks if necessary.
or other unnecessary parts will be disassem- 4) Other maintenance items can be checked
bled. externally, so check any item that is consid-
• It will become impossible to find the cause of ered to be necessary.
the failure. 5) Check for any error display on the controller.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose 4. Confirming failure
the confidence of the user or operator. Confirm the extent of the failure yourself, and
For this reason, when carrying out troubleshoot- judge whether to handle it as a real failure or as
ing, it is necessary to carry out thorough prior a problem with the method of operation, etc.
investigation and to carry out troubleshooting in a When operating the machine to re-enact the
accordance with the fixed procedure. troubleshooting symptoms, do not carry out
any investigation or measurement that may
2. Points to ask user or operator make the problem worse.
1) Have any other problems occurred apart
from the problem that has been reported? 5. Troubleshooting
2) Was there anything strange about the Us e th e r e s u l ts o f t he i nv e s ti g a ti o n a n d
machine before the failure occurred? inspection in Items 2 – 4 to narrow down the
3) Did the failure occur suddenly, or were there causes of failure, then use the troubleshooting
problems with the machine condition before matrix or flowchart to locate the position of the
this? failure exactly.
4) Under what conditions did the failure occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before the as follows.
failure? When were these repairs carried 1) Start from the simple points.
out? 2) Start from the most likely points.
6) Has the same kind of failure occurred 3) Investigate other related parts or informa-
before? tion.
6. Measures to remove root cause of failure

Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root cause.
20-702 PC750, 800-7

(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections + in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in are
items that can be obtained from the user,
depending on the user's level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information that he has obtained from the
user and the results of that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with , and of these, causes that have a high prob-
ability are marked with .
Check each of the [Questions] and [Check items]
in turn, and marked the or in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if nec-
essary to determine the order for troubleshooting.
Use the in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
PC750, 800-7 20-703

(1)
<Example of troubleshooting> Exhaust smoke is black
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black

• Insufficient intake of air
• There is excessive fuel.
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited because
an error has occurred in the electrical system.)
20-704 PC750, 800-7

(1)
PC750, 800-7 20-705

(1)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (starting always takes time)
General causes why starting performance is poor

• Defective electrical system
• Insufficient supply of fuel
a With the common rail fuel injection system, the

fuel injection timing is recognized electrically, so
even when the starting operation is carried out,
the engine may not start until the crankshaft has
completed two rotations. However, this does
not indicate any abnormality.
20-706 PC750, 800-7

(1)
TROUBLESHOOTING S-2
S-2 Engine does not start
a) Engine does not turn

General causes why engine does not turn
• Internal parts of engine seized
a See "Engine stops during operations".
• Defective electrical system
• Failure on chassis side
PC750, 800-7 20-707

(1)
TROUBLESHOOTING S-2
b) Engine turns but no exhaust smoke comes out

General causes why engine turns but no exhaust
smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
20-708 PC750, 800-7

(1)
TROUBLESHOOTING S-2
c) Exhaust smoke comes out but engine does not

start (Fuel is being injected)
General causes why exhaust smoke comes out
but engine does not start
• Lack of rotating force due to defective electrical
system
PC750, 800-7 20-709

(1)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (follow-up is poor)
General causes why engine does not pick up smoothly

20-710 PC750, 800-7

(1)
TROUBLESHOOTING S-4
S-4 Engine stops during operations
General causes why engine stops

• Internal part of engine seized
• Failure on chassis side
PC750, 800-7 20-711

(1)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly

• Air in fuel system
• Speed sensor is not normal
(abnormality not big enough to generate error display)
20-712 PC750, 800-7

(1)
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output

PC750, 800-7 20-713

(1)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black

• There is excessive fuel.
20-714 PC750, 800-7

(1)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive

• Abnormal combustion of oil
• The engine has been run at low or high idling for a
long time continuously (more than 20 minutes con-
tinuous operation is not allowed).
• External leakage of oil
• Wear of lubrication system
PC750, 800-7 20-715

(1)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly

• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Improper fuel used
• Improper oil used
• Operation under excessive load
20-716 PC750, 800-7

(1)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

• Leakage of fuel
• Improper condition of fuel injection (injection pressure,
injection timing)
• Excessive injection of fuel
PC750, 800-7 20-717

(1)
S-11 Oil is in cooling water (or water spurts back, or water level goes down)
General causes why oil is in cooling water

• Internal leakage in lubrication system
• Internal leakage in cooling system
20-718 PC750, 800-7

(1)
S-12 Oil pressure caution lamp lights up (drop in oil pressure)
General causes why oil pressure drops

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
PC750, 800-7 20-719

(1)
S-13 Oil level rises (water, fuel in oil)
General causes why oil level rises

• Water in oil (cloudy white)
• Fuel in oil (diluted, smells of diesel fuel)
a If there is oil in the cooling water, carry out troubleshooting

for "Oil is in cooling water".
20-720 PC750, 800-7

(1)
S-14 Water temperature becomes too high (overheating)
General causes why water temperature becomes too high

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise of hydraulic oil temperature on chassis side
PC750, 800-7 20-721

(1)
S-15 Abnormal noise is made
General causes why abnormal noise is made

• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
a Judge if the noise is an internal noise or an external noise.

a If the engine is not thoroughly warmed up, the engine
sound becomes slightly louder because it is operated in the
low temperature mode, but this is not an abnormality.
a When the engine is accelerated, it enters the acceleration
mode and the engine noise is higher for 3 seconds, but this
is not an abnormality.
20-722 PC750, 800-7

(1)
S-16 Vibration is excessive
General causes why vibration is excessive

• Defective parts (abnormal wear, breakage)
• Improper alignment with machine
• Abnormal combustion
a If there is abnormal noise together with the vibration, carry

out troubleshooting also for "Abnormal noise is made".
PC750, 800-7 20-723

(1)
30 DISASSEMBLY AND
ASSEMBLY
METHOD OF USING MANUAL.....................30- 3 REMOVAL AND INSTALLATION OF

PRECAUTIONS WHEN CARRYING OUT CARRIER ROLLER ASSEMBLY ............. 30- 65
OPERATION ............................................30- 5 DISASSEMBLY AND ASSEMBLY OF
SPECIAL TOOL LIST .................................... 30- 7 CARRIER ROLLER ASSEMBLY ............. 30- 66
REMOVAL AND INSTALLATION OF REMOVAL AND INSTALLATION OF
AFTERCOOLER CORE...........................30- 14 TRACK ROLLER ASSEMBLY ................. 30- 69
REMOVAL AND INSTALLATION OF FAN DISASSEMBLY AND ASSEMBLY OF
GUARD, RADIATOR AND HYDRAULIC TRACK ROLLER ASSEMBLY ................. 30- 70
OIL COOLER ASSEMBLY ....................... 30- 15 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF FUEL HYDRAULIC TANK ASSEMBLY.............. 30- 73
COOLER AND AIR CONDITIONER REMOVAL AND INSTALLATION OF MAIN
CONDENSER ASSEMBLY ...................... 30- 18 PUMP (NO. 1 PUMP) ASSEMBLY .......... 30- 75
REMOVAL AND INSTALLATION OF FUEL REMOVAL AND INSTALLATION OF MAIN
TANK ASSEMBLY.................................... 30- 19 PUMP (NO. 2 PUMP) .............................. 30- 77
REMOVAL AND INSTALLATION OF REMOVAL AND INSTALLATION OF MAIN
ENGINE, PTO AND HYDRAULIC PUMP INPUT SHAFT OIL SEAL ............. 30- 79
PUMP ASSEMBLY................................... 30- 20 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF PTO CONTROL AND PTO LUBRICATION
ASSEMBLY .............................................. 30- 24 PUMP ASSEMBLY .................................. 30- 80
DISASSEMBLY AND ASSEMBLY OF PTO DISASSEMBLY AND ASSEMBLY OF MAIN
ASSEMBLY .............................................. 30- 26 RELIEF VALVE ASSEMBLY .................... 30- 81
DISASSEMBLY AND ASSEMBLY OF REMOVAL AND INSTALLATION OF
FINAL DRIVE ASSEMBLY....................... 30- 29 CONTROL VALVE ASSEMBLY ............... 30- 82
REMOVAL AND INSTALLATION OF DISASSEMBLY AND ASSEMBLY OF
REVOLVING FRAME ASSEMBLY...........30- 40 CONTROL VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF (WORK EQUIPMENT) ............................. 30- 85
SWING MACHINERY ASSEMBLY .......... 30- 41 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF SOLENOID VALVE ASSEMBLY .............. 30- 88
SWING MACHINERY ASSEMBLY .......... 30- 42 REMOVAL AND INSTALLATION OF BOOM
REMOVAL AND INSTALLATION OF DAMPING VALVE ASSEMBLY................ 30- 90
SWING CIRCLE ASSEMBLY................... 30- 49 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY .................. 30- 91
TRACK SHOE ASSEMBLY...................... 30- 50 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF ONE CENTER SWIVEL JOINT ........................ 30- 93
LINK IN FIELD .........................................30- 52 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF IDLER CENTER SWIVEL JOINT ASSEMBLY .... 30- 94
ASSEMBLY .............................................. 30- 56 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR ASSEMBLY................. 30- 96
IDLER ASSEMBLY ..................................30- 57 DISASSEMBLY AND ASSEMBLY OF
DISASSEMBLY AND ASSEMBLY OF IDLER WORK EQUIPMENT PPC VALVE
ADJUSTMENT CYLINDER ASSEMBLY..30- 60 ASSEMBLY.............................................. 30- 97
REMOVAL AND INSTALLATION OF DISASSEMBLY AND ASSEMBLY OF
RECOIL SPRING ASSEMBLY ................. 30- 61 TRAVEL PPC VALVE ASSEMBLY........... 30- 99
DISASSEMBLY AND ASSEMBLY OF REMOVAL AND INSTALLATION OF BUCKET
RECOIL SPRING ASSEMBLY................ 30- 63 CYLINDER ASSEMBLY (BACK HOE)..... 30-101
PC750, 800-7 30-1

(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF BUCKET

CYLINDER ASSEMBLY
(LOADING SHOVEL)............................... 30-103
REMOVAL AND INSTALLATION OF ARM
CYLINDER ASSEMBLY (BACK HOE) .... 30-105
CYLINDER ASSEMBLY
(LOADING SHOVEL)............................... 30-107
REMOVAL AND INSTALLATION OF BOOM
CYLINDER ASSEMBLY (BACK HOE) .... 30-109
CYLINDER ASSEMBLY
(LOADING SHOVEL)............................... 30- 111
REMOVAL AND INSTALLATION OF BOTTOM
DUMP CYLINDER ASSEMBLY
(LOADING SHOVEL)............................... 30-113
DISASSEMBLY AND ASSEMBLY OF
HYDRAULIC CYLINDER ASSEMBLY..... 30-114
ASSEMBLY (BACK HOE)........................ 30-120
ASSEMBLY (LOADING SHOVEL) .......... 30-121
REMOVAL AND INSTALLATION OF WORK
EQUIPMENT (BACK HOE) ..................... 30-130
REMOVAL AND INSTALLATION OF WORK
EQUIPMENT (LOADING SHOVEL) ........ 30-132
REMOVAL AND INSTALLATION OF
OPERATOR’S CAB ASSEMBLY ............. 30-134
OPERATOR’S CAB GLASS
(STUCK GLASS) ..................................... 30-136
REMOVAL AND INSTALLATION OF FRONT
WINDOW ASSEMBLY ............................. 30-146
COUNTERWEIGHT ASSEMBLY............. 30-152
30-2 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

REMOVAL AND INSTALLATION OF ASSEMBLIES
SPECIAL TOOLS INSTALLATION OF PARTS

• Special tools that are deemed necessary for • Except where otherwise instructed, install parts
removal or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing parts
kind of information. are shown with mark in the INSTALLA-
1) Necessity TION Section, identifying which step the instruc-
t: Special tools which cannot be substi- tions are intended for.
tuted, should always be used. • Marks shown in the INSTALLATION Section
q: Special tools which are very useful if stand for the following.
k
available, can be substituted with com-
mercially available tools. This mark indicates safety-related pre-
cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly a This mark gives guidance or precau-
developed for this model.
2 This mark stands for a specific coating
tions when doing the procedure.
R: Tools with upgraded part numbers,
remodeled from already available tools
3 This mark indicates the specified
agent to be used.
for other models.
Blank: Tools already available for other mod-
5
torque.
els, used without any modification. This mark indicates an amount of oil or
3) Circle mark (Q) in sketch column: water to be added.
A circle mark means that a sketch of the
special tool is presented in the section of
Sketches for Special Tools. SKETCHES OF SPECIAL TOOLS
a Part No. of special tools starting with 79*T means • Various special tools are illustrated for the con-
that they are locally made parts and as such not venience of local manufacture.
interchangeable with those made by Komatsu in
Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL OF PARTS
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
k This mark indicates safety-related pre-

doing the work.
a This mark gives guidance or precautions
when doing the procedure.
This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be

drained.
PC750, 800-7 30-3

(2)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
SPECIAL TOOLS ASSEMBLY

• Special tools which are deemed necessary for • Section titled ASSEMBLY contain procedures,
disassembly and assembly are listed in this sec- precautions and the know-how for the work, as
tion. well as the amount of oil or water to be added.
• List of the special tools contains the following • Various symbols used in the ASSEMBLY Sec-
kind of information. tion are explained and listed below.
k
1) Necessity
t: Special tools which cannot be substi- This mark indicates safety-related pre-
tuted, should always be used. cautions which must be followed when
q: Special tools which are very useful if doing the work.
available, can be substituted with com- a This mark gives guidance or precau-
2 This mark stands for a specific coating

mercially available tools. tions when doing the procedure.
2) Distinction of new and existing special tools
3 This mark indicates the specified
agent to be used.
N: Tools with new part numbers, newly
developed for this model.
5
torque.
R: Tools with upgraded part numbers,
This mark indicates an amount of oil or
remodeled from already available tools
water to be added.
for other models.
Blank: Tools already available for other mod-
els, used without any modification.
SKETCHES OF SPECIAL TOOLS
3) Circle mark (Q) in sketch column: 1) Various special tools are illustrated for the
A circle mark means that a sketch of the convenience of local manufacture.
special tool is presented in the section of
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T
means that they are locally made parts and
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T--- xxx
--- xxxx.
DISASSEMBLY
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or
water to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
k This mark indicates safety-related pre-

doing the work.
a This mark gives guidance or precautions
when doing the procedure.
This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be

drained.
30-4 PC750, 800-7

(2)
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 pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting 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 enter-
ing after removal.
a Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal number Plug (nut end) Nut (elbow end)

02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
Taper 1/8
12 07049-01215 12 10 15
øD
ød
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22 L
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28 DEW00401
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
PC750, 800-7 30-5

(2)
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.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic 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 cyl-
inder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

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

(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79 T- - cannot be supplied (they are items to be locally manufac-
tured).
a Necessity: t............Cannot be substituted, must always be installed (used)

q............Extremely useful if available or can be substituted with commercially available part
a New/Remodel: N ...........Tools with new part numbers, newly developed for this model
R: ...........Tools with upgraded part numbers, remodeled from items already available for oth-
er models
Blank: ... Tools already available for other models, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See SKETCH-
ES OF SPECIAL TOOLS).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
790-101-5401 Push tool kit t 1
Disassembly, assembly
• 790-101-5541 • Plate t 1
1 Press fitting of oil seal
• 790-101-5421 • Grip t 1
• 01010-81240 • Bolt t 1
Swing machinery
F Press fitting of main bear-
assembly 790-201-2780 Spacer t 1
ing
2
Press fitting of main bear-
790-201-2880 Spacer t 1
ing
3 796T-626-1130 Push tool t 1 N Q Press fitting of sub bearing
1 796-627-1050 Installer t 1 Installation of floating seal
Press fitting of bearing
2 796-627-1030 Push tool t 1 R
outer race
790-101-2300 Push-puller t 1
• 790-101-2310 • Block t 1
• 790-101-2350 • Leg t 2
• 790-101-2360 • Plate t 2
inner race
• 02215-11622 • Nut t 2
3
791-181-1010 Adapter t 2
Final drive 796T-627-1340 Push tool t 1 N Q
J
assembly Puller
790-101-2102 t 1 Long stroke
(294 kN {30 ton})
790-101-1102 Pump t 1
Removal, installation of
4 790-627-1200 Wrench assembly t 1 N
round nut
796-627-1070 Spacer t 1 N
Removal of No. 1 carrier
5 01017-52450 Bolt t 1
pin holder
01580-12419 Nut t 1
790-201-2830 Spacer t 1 Removal of No. 1 carrier
6
790-101-5151 Plate t 1 pin
PC750, 800-7 30-7

(2)
New/remodel
Necessity
Symbol
Sketch
Q'ty
790-101-5401 Push tool kit (C) t 1

• 790-101-5441 • Plate t 1
7
• 790-101-5421 • Grip t 1 outer race
• 01010-51240 • Bolt t 1
Final drive
J Press fitting of needle
assembly 790-101-5001 Push tool kit (A) t 1
bearing
8 • 790-101-5151 • Plate t 1 No. 2 carrier
• 790-101-5061 • Plate t 1 No. 3 carrier
• 790-101-5021 • Grip t 1
installation
Disassembly, Removal,
Travel motor Removal, installation of
K 796-660-1560 Guide bolt t 2 N
assembly travel motor assembly
Press fitting of idler bush-

1 790-201-2680 Plate t 1
assembly
ing
Idler assembly
Installation of idler floating
2 796-675-1510 Installer t 1
seal
Press fitting of carrier roller
3 790-1101-5401 Push tool kit (C) t 1 Disassembly, bearing
assembly
Carrier roller 4 796T-630-1130 Push tool t 1 Installation of floating seal
assembly Press fitting of carrier roller
5 796T-630-1140 Adapter t 1 N Q
bearing inner race
790-401-1700 Lifting tool t 1
L
790-401-1761 Adapter t 1 Removal, installation of
7
790-401-1540 Shackle t 2 track roller assembly
790-401-1770 T-bolt t 2
Track roller
assembly Press fitting of track roller
9 790-201-2670 Plate t 1
bushing
791-601-1000 Oil pump t 1
or t Filling with oil, checking
10
791-646-8002 Oil lubricator t 1 sealing
790-701-3000 Seal checker t 1
30-8 PC750, 800-7

(2)
New/remodel
Necessity
Symbol
Sketch
Q'ty
791-680-9501 Remover, installer t 1
Removal, installation
Cylinder (1,471 kN
790-101-4300 t 1
{150 ton}) Removal, installation of
Track shoe 1
Puller master pin
assembly 790-101-4200 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
2 790-331-1100 Wrench t 1 Tightening shoe bolt angle
791-685-8501 Compressor t 1
M
791-635-3160 Extension t 1
796-630-1110 Plate t 1
01010-51640 Bolt t 2
Recoil spring Disassembly, assembly of
3 796-630-1120 Spacer t 1
assembly recoil spring
Cylinder (686 kN
790-101-1600 t 1
{70 ton})
790-010-1102 Pump t 1
796-630-1110 Plate t 1
791-680-9580 Adapter t 1
791-680-9590 Guide t 1
1
01010-52760 Bolt t 2
01010-51440 Bolt t 2
790-101-1102 Pump t 1
2
790-101-4300 Cylinder t 1 1,471 kN {150 ton}
791-685-9510 Frame t 1
791-685-9520 Frame t 1
Assembly
Track link remover N 791-685-9530 Rod t 1

791-685-9550 Nut t 1
791-685-9560 Bolt t 4
3
791-680-9570 Adapter t 1
01010-51030 Bolt t 1
04530-12030 Eyebolt t 1
Disassembly,
assembly
790-101-1102 Pump t 1
790-101-4300 Cylinder t 1 1,471 kN {150 ton}
791-685-9540 Rod t 1
4
791-685-9550 Nut t 3
PC750, 800-7 30-9

(2)
New/remodel
Necessity
Symbol
Sketch
Q'ty
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9550 Nut t 1
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
791-680-5520 Guide t 1
5
791-126-0140 Pusher t 1
Track link remover
791-680-9570 Adapter t 1
01010-51030 Bolt t 1
04530-12030 Eyebolt t 1
791-685-9620 Extension t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder t 1 1,471 kN {150 ton}
790-101-1102 Pump t 1
6
790-101-4200 Pulley t 1 294 kN {30 ton}
791-680-5542 Adapter t 1 Disassembly
Press fitting of regular pin
7
791-632-1110 Adapter t 1 Press fitting of bushing
8 791-680-5580 Guide t 1
791-685-9510 Frame t 1
N
791-685-9520 Frame t 1
791-685-9530 Rod t 1
Assembly
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
9 791-126-0150 Adapter t 1
01010-51030 Bolt t 1
791-685-9620 Extension t 1
Track link installer
791-680-5542 Adapter t 1
791-680-5560 Guide t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder t 1 1,471 kN {150 ton}

791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
10
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
01010-51030 Bolt t 1
30-10 PC750, 800-7

(2)
New/remodel
Necessity
Symbol
Sketch
Q'ty
791-685-9620 Extension t 1
791-680-5560 Guide t 1
791-632-1110 Adapter t 1
10
791-680-9630 Adapter t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder t 1 1,471 kN {150 ton}
11 791-680-1520 Guide t 1
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
Track link installer
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
N
12 791-126-0150 Adapter t 1
791-680-5560 Guide t 1
791-680-9570 Adapter t 1
01010-51030 Bolt t 1
791-680-1520 Guide t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder t 1 1,471 kN {150 ton}
790-101-1102 Pump t 1
13
790-101-4200 Pulley t 1 294 kN {30 ton}
791-680-9501 Remover, installer t 1 Kit
Track link 790-101-1102 Pump t 1
14
remover, installer 790-101-4200 Pulley t 1 294 kN {30 ton}
790-101-4300 Cylinder t 1 1,471 kN {150 ton}
installation
Removal,
Removal, installation of
1 796-770-1301 Oil stopper t 1
hydraulic pump
2 209-60-71130 Rod assembly t 1

Hydraulic pump
S 3 790-101-5001 Push tool kit t 1
assembly
Press fitting of oil seal
4 • 790-101-5151 • Plate t 1 (hydraulic pump shaft)
5 • 790-101-5021 • Grip t 1
6 01010-50816 • Bolt t 1
PC750, 800-7 30-11

(2)
New/remodel
Necessity
Symbol
Sketch
Q'ty
790-101-2501 Push-puller t 1
• 790-101-2510 • Block t 1
• 790-101-2520 • Screw t 1
• 791-112-1180 • Nut t 1
Center swivel joint Disassembly of center
T • 790-101-2540 • Washer t 1
assembly swivel joint
• 790-101-2630 • Leg t 2
• 790-101-2570 • Plate t 2
• 790-101-2560 • Nut t 2
• 790-101-2660 • Adapter t 2
Cylinder repair Disassembly, assembly of
1 790-502-1003 t 2
stand hydraulic cylinder
2 790-720-1000 Expander t 1 N Q Installation of piston ring
Disassembly
796-720-1690 Ring t 1 Boom, arm cylinder
796-720-1720 Ring t 1 Bucket cylinder (for SE)
07281-02169 Clamp t 1 Boom, arm cylinder
3
796-720-1690 Ring t 1
Bucket cylinder
07281-01919 Clamp t 1
07281-02429 Clamp t 1 Bucket cylinder (for SE)
790-201-1702 Push tool kit t 1 Press fitting of coil bushing
• 790-201-1881 • Push tool t 1 Boom, arm cylinder
Arm cylinder (for
• 790-201-1871 • Push tool t 1 SE), bucket cylin-
Assembly
der
Hydraulic cylinder 4 • 791-863-1110 • Push tool
U t 1
assembly Bucket cylinder
• 790-101-5421 • Grip t 1
(for SE)
• 01010-51240 • Bolt t 1
• 790-101-5021 • Grip t 1
All cylinders
• 01010-50816 • Bolt t 1
790-201-1500 Push tool kit t 1 Press fitting of dust seal
• 790-201-1690 • Plate t 1 Boom, arm cylinder
Assembly
• 790-201-1680 • Plate t 1 Bucket cylinder

5
• 792-715-1400 • Push tool t 1
Bucket cylinder
• 790-101-5421 • Grip t 1
(for SE)
• 01010-51240 • Bolt t 1
Disassembly,
• 790-101-5021 • Grip t 1
assembly
Press fitting of dust seal

6
All cylinders
• 01010-51240 • Bolt t 1
30-12 PC750, 800-7

(2)
New/remodel
Necessity
Symbol
Sketch
Q'ty
Removal of boom foot pin,

790-445-4100 Remover t 1
boom cylinder bottom pin
1 Puller
790-101-4200 t 1 Short stroke
(294 kN {30 ton})
790-101-1102 Pump t 1
791-650-1610 Bracket t 1
790-445-4130 Screw t 1 Removal of arm cylinder
791-112-1180 Nut t 1 rod head and bottom pin
2 01643-32780 Washer t 1
Puller
Work equipment 790-101-2102 t 1 Long stroke
V (294 kN {30 ton})
assembly
790-101-1102 Pump t 1
790-445-4120 Sleeve t 1 Removal of boom top pin
and boom cylinder head
791-520-4140 Screw t 1 pin
796-775-1110 Adapter t 1 Boom top pin only
3 791-112-1180 Nut t 1
01643-32780 Washer t 1
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Sleeve t 1
799-703-1200 Service tool kit t 1
Vacuum pump
799-703-1100 t 1
(100 V)
Air conditioner Vacuum pump Charging with freon gas
X 799-703-1110 t 1
system (220 V) (R134a)
Vacuum pump
799-703-1120 t 1
(240 V)
799-703-1400 Gas leak detector t 1
Lifter
Installation
1 793-498-1210 t 2
Operator’s cab (Suction cup) Installation of operator’s
Y
glass cab glass
2 20Y-54-13180 Adapter t 2
PC750, 800-7 30-13

(2)
DISASSEMBLY AND ASSEMBLY AFTERCOOLER CORE
REMOVAL AND INSTALLATION OF AFTERCOOLER CORE
REMOVAL INSTALLATION
1. Lift off radiator grille (1). • Carry out installation in the reverse order to
removal.
2. Lift off radiator top cover (2).
3. Loosen clamps (3) of rubber hose.
4. Sling aftercooler core (4), remove mounting

bolts, and pull out from rubber hose while lifting
off.
30-14 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER
REMOVAL AND INSTALLATION OF FAN GUARD, RADIATOR

AND HYDRAULIC OIL COOLER ASSEMBLY
SPECIAL TOOLS 3. Remove the radiator grille (2) and the cover (3).
New/Remodel
4. Loosen 2 bolts of the radiator grille (2) and open
Necessity
the grille.
Symbol
Sketch
Q’ty
Part No. Part Name a Remove the air conditioner condenser, the
fuel cooler and the after cooler referring to
the paragraph of Removal of Air Conditioner
Condenser, Fuel Cooler and After Cooler.
Vacuum pump
799-703-1100 t 1
(100V)
Vacuum pump
X 799-703-1110 t 1
(220V)
Vacuum pump
799-703-1120 t 1
(240V)
Gas leak
799-703-1400 t 1
detector (100V)
REMOVAL
k Disconnect the (–) terminal of the battery in ad-
vance.
k Open the engine hood, and press the valve of
5. Remove the brackets (5) of the air conditioner
condenser and the fuel cooler.
the compressor hose for the air conditioner
slowly to release refrigerant (R134a) gradually.
k Lower the work equipment completely to the
ground and stop the engine. Loosen the oil filler
cap of the hydraulic tank slowly to release the in-
ternal 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.
6. Disconnect the radiator cooler tube (6) and the

radiator cooler hose (7).
7. Remove the fuel cooler hose clamp (8).
PC750, 800-7 30-15

(2)
8. Remove 3 pieces of the hose clamp (9) of the air 14. Lift the fan guard, radiator and hydraulic oil
conditioner condenser. cooler assembly temporarily and remove the
mounting bolts (17).
9. Remove 2 pieces of the plate (10).
15. Remove the fan guard, radiator and hydraulic oil
cooler assembly (18).
4 Fan guard, radiator and hydraulic oil

cooler assembly: 950 kg
10. Disconnect the air intake hose (11) and the air
intake tube (12).
11. Disconnect the hoses (13), (14) and (15).
12. Reduce the tension of the tension pulley by

using a lever block, for example, and remove
the fan belt.
16. Lower the fan pulley and set the block

between the fan guard, radiator and hydraulic oil
cooler assembly and the ground.
13. Loosen the bolt of the frame (16) and remove it.
17. Lift the hydraulic oil cooler assembly (19) tempo-
rarily, remove 8 pieces of the mounting bolt (20)
and then remove the hydraulic oil cooler assem-
bly.
4 Hydraulic oil cooler assembly: 200 kg
18. Lift the radiator (21) temporarily and remove 8

pieces of the mounting bolt (22).
30-16 PC750, 800-7

(2)
INSTALLATION
• To install this assembly, reverse the removing
procedures.
• Water Filling
a Fill water up to the specified level through the
water filler port, start the engine to circulate
coolant and check the water level again.
• Filling (Hydraulic Tank) with Oil

a Fill oil up to the specified level through the oil
filler port, start the engine to circulate oil
through the pipe and check the oil level
again.
19. Remove the isolator (23) and then remove the
radiator assembly. • Filling of Air Conditioner Gas
a Use the tool X and fill the air conditioner cir-
4 Radiator assembly: 260 kg cuit with refrigerant (R134a).
• Alignment of Engine Pulley and Fan Pulley

a Assemble them so that the engine pulley
aligns with the fan pulley within 3 mm.
• Filling (Fuel Tank) with Diesel Fuel

a Fill the fuel tank with diesel fuel through the
oil filler port and bleed air by the specified
method (See the Operation and Mainte-
nance Manual).
PC750, 800-7 30-17

(2)
DISASSEMBLY AND ASSEMBLY FUEL COOLER AND AIR CONDITIONER CONDENSER
REMOVAL AND INSTALLATION OF FUEL COOLER AND AIR

CONDITIONER CONDENSER ASSEMBLY
SPECIAL TOOLS 3. Remove the fuel cooler guard (3).
New/Remodel
4. Disconnect the fuel cooler hose quick coupler
Necessity
(4) and (5).
Symbol
Sketch
Q’ty
Part No. Part Name
5. Loosen 4 pieces of the fuel cooler mounting bolt
(6) and remove the fuel cooler (7).
Vacuum pump
799-703-1100 t 1
(100V)
Vacuum pump
X 799-703-1110 t 1
(220V)
Vacuum pump
799-703-1120 t 1
(240V)
Gas leak
799-703-1400 t 1
detector (100V)
REMOVAL
k
6. Disconnect the air conditioner condenser hoses
Lower the work equipment completely to the
(8) and (9).
ground and stop the engine. Loosen the cap of
the hydraulic tank slowly to release the internal
7. Loosen 4 pieces of the air conditioner con-
k Connect the tool X to the valve of the air com-
denser mounting bolt (10) and remove the air
conditioner condenser (11).
pressor hose and recall new Freon gas (R134a).
1. Shut the valve (1) of the fuel tank.
INSTALLATION
•To install this assembly, reverse the removing
2. Open the radiator grille (2).
procedures.
a Fill new Freon gas (R134a).
30-18 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
REMOVAL 5. Disconnect the fuel supply hose (5) and the

k Disconnect the (–) terminal of the battery in ad- drain hose (6).
vance.
1. Open the drain valve and drain fuel.
6 Fuel tank:
880 l (when the tank is fully filled)
2. Remove the handrail (1).
6. Remove the control valve cover bracket (7).
3. Remove the fuel gauge cover (2) and the fuel

gauge wiring cover (3), and disconnect the wir-
ing connector.
7. Loosen the mounting bolt, lift the fuel tank

assembly and remove it.
4 Fuel tank assembly: 498 kg
4. Disconnect the fuel return hoses (4) and (5) and

remove the hose clamps.
INSTALLATION
3 Fuel tank mounting bolt:

procedures.
549 ± 58 Nm {56 ± 6kgm}
PC750, 800-7 30-19

(2)
DISASSEMBLY AND ASSEMBLY ENGINE, PTO AND HYDRAULIC PUMP
REMOVAL AND INSTALLATION OF ENGINE, PTO AND

HYDRAULIC PUMP ASSEMBLY
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
S 1 796-770-1301 Oil stopper t 1
REMOVAL
the hydraulic tank slowly to release internal
4. Remove the radiator cover (4).
k Drain engine oil.
k Disconnect the (–) terminal of the battery.
5. Remove the engine hood (5).
a Put counter marks on each hose and tube, and
6. Remove the main pump cover (6).
attach oil stopper plugs to the disconnected hos-
es and tubes.
1. Remove the strainer from the fuel tank and use

the oil stopper tool S1 to stop oil flow.
• When the tool S1 is not used, remove the
drain plug and drain oil.
6 Hydraulic tank: 500 l
2. Drain coolant.
3. Remove the engine oil filter cover (1) and

remove the oil filter assembly (2) together with
the bracket (3) from the engine hood. Place 7. Remove the partition cover (7) between the
them on the control valve side. engine and the main pump.
30-20 PC750, 800-7

(2)
Engine Left Side 14. Disconnect the air cleaner dust indicator hose
8. Remove the air compressor cover (8) and (19) and remove the wiring connector (20).
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.
Engine Right Side

15. Disconnect the aftercooler hose (21).
16. Disconnect the aeration hose (22) and the cool-

ant hose (23).
11. Remove the fuel cooler hose (11), the fuel hose
(12), the hose clamp (13), the engine breather
hose (14) and the clamp of the muffler drain
hose (15).
17. Disconnect the car heater hose (24) and the

hose clamp (25).
18. Disconnect the coolant hose (26).
12. Remove the wiring connector (16) and the wiring

clamp (17).
13. Disconnect the engine oil filter hose (18).
PC750, 800-7 30-21

(2)
19. Reduce the tension of the tension pulley (27) 24. Disconnect the servo valve hose (36) and the
and remove the fan belt (28). safety valve hose (37).
20. Disconnect the starter wiring (29) and the 25. Disconnect the control pump outlet hose (38).
ground cable (30).
26. Disconnect the outlet hoses (39) and (40) of No.
1 and No. 2 pumps and the drain hoses (41) and
(42).
21. Remove the TVC solenoid connector (31) and

the clamp, and disconnect the harness from the
pump.
27. Disconnect the suction tubes (43) and (44) and
22. Disconnect the jet sensor hoses (32) and (33) of the suction hose (45).
No. 1 pump.
23. Disconnect the CO cancel hose (34) and the

pilot pressure reducing hose (35).
30-22 PC750, 800-7

(2)
28. Lift the engine, PTO and pump assembly tempo-

rarily and remove the front mounting bolt (46),
the rear mounting bolt (47), the left and right
mounting bolts.
INSTALLATION
3 Mounting bolt:
procedures.
926.1 ± 102.9 Nm {94.5 ± 10.5 kgm}
• Oil Filling
a Fill oil up to the specified level, start the en-
gine to circulate oil throughout the pipe and
check the oil level.
• Water Filling
a Fill water up to the specified level, start the
engine to circulate coolant throughout the
pipe and check the water level.
29. Lift the engine, PTO and pump assembly (48)
and remove it. • Air Bleeding
a Lift the assembly a little to prevent the fan Bleed air from the main pump referring to the
pulley from interfering, take out the front paragraph of "Bleeding Air from Main Pump" in
mount, slide it backward and lift the assem- Testing and Adjusting.
bly.
4 Engine, PTO and pump assembly:

26,000 kg
PC750, 800-7 30-23

(2)
DISASSEMBLY AND ASSEMBLY PTO
REMOVAL AND INSTALLATION OF PTO ASSEMBLY

REMOVAL 5. Disconnect the lubrication hoses (7) and (11),
1. Remove the engine, PTO and hydraulic pump the lubrication tubes (4), (5), (6), (8), (9) and
assembly referring to the paragraph of (10), and remove the block (12).
"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. 2 pump assembly: 150 kg
4. Lift the control, PTO and lubrication pump

assembly (3) and remove it.
a Take out the suction hose as well at the
same time. 6. Lift the PTO assembly (13) and remove it.
4 PTO assembly: 500 kg
30-24 PC750, 800-7

(2)
7. Lift the shaft (14) and remove it. INSTALLATION

8. Remove the coupling (15). procedures.
9. Remove the plate (16).

3 Bolt:
110.3 ± 12.2 Nm {11.25 ± 1.25 kgm}
3 Bolt:
277.05 ± 31.85 Nm {28.25 ± 3.25 kgm}
PC750, 800-7 30-25

(2)
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY

DISASSEMBLY 3. Removal of bearing
1. Cover Using puller , remove bearing from each gear.
Remove mounting bolts, then using bolt ,
remove case (3).
a Check the number and thickness of the
shims, and keep in a safe place.
ASSEMBLY
a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
2. Gear assembly oil before installing.
Remove gear assemblies (5), (6), and (7).
a If the gear assembly will not come out, re- 1. Bearings
move nipple (8), then use a puller to remove Install bearings (9), (10), (11), (12), and (13) to
the gear assembly from the case. gears (5), (6), and (7).
30-26 PC750, 800-7

(2)
2. Outer race at case end 5. Case
2 Gasket: Gasket sealant (LG-1)

Press fit outer race (14) to case (15). Fit gasket and install case (3).
3. Nipples, plug 3 Bolt:

Install nipples (8) and plug (16). 110.25 ± 12.25 Nm {11.25 ± 1.25 kgm}
4. Gears a After tightening the bolts, check that the

1) Install gears (5) and (7). thickness of the gasket is the dimension
2) Install gear (6). shown in the diagram below.
3) Rotate gears, check that each gear rotates
smoothly, then coat with red lead (minium),
2 Bearing: Grease (G2-LI)

and check tooth contact.
PC750, 800-7 30-27

(2)
Adjusting cover shim

a 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 .
3) Calculate clearance F + clearance G, and
determine the thickness of the shim accord-
ing to the following table.
Clearance Thickness, part number of

F+G shim to use Overall
(mm) thickness
21N-30- 21N-33- 21N-38-
of shim
1250 1260 1270
From To (mm)
(0.1mm) (0.2mm) (0.5mm)
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 Gasket: Gasket sealant (LG-1)

2.72 2.92 1 3 1.7 6. Fit gasket and install cover (19).
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
30-28 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

SPECIAL TOOLS DISASSEMBLY
1. Draining oil
New/Remodel
Remove drain plug and drain oil from final drive
Necessity
Symbol
case.
Sketch
Q’ty
Part No. Part Name
6 Final drive case: Approx. 20 l
1 796-627-1050 Installer t 1 2. Put travel motor at bottom and set on block of

height approx. 350 mm.
2 796-627-1030 Push tool t 1 R
3. Cover
790-101-2300 Push-puller t 1
Using forcing screws and eyebolts , remove
• 790-101-2310 • Block t 1 cover (1).
• 790-101-2350 • Leg t 2
• 790-101-2360 • Plate t 2
3 • 02215-11622 • Nut t 2
791-181-1010 Adapter t 2
796T-627-1340 Push tool t 1 N Q
Puller (294kN
790-101-2102 t 1
{30 ton})
790-101-1102 Pump t 1
Wrench
4 790-627-1200 t 1 N
assembly 4. No. 3 carrier assembly
J 796-627-1070 Spacer t 1 N 1) Remove thrust washer (50).
2) Using eyebolts , remove No. 3 carrier
5 01017-52450 Bolt t 1 assembly (2).
01580-12419 Nut t 1
790-201-2830 Spacer t 1
6
790-101-5151 Plate t 1
Push tool kit
790-101-5401 t 1
(C)
• 790-101-5441 • Plate t 1
7
• 790-101-5421 • Grip t 1
• 01010-51240 • Bolt t 1
Push tool kit
790-101-5001 t 1
(A)
• 790-101-5151 • Plate t 1
8
• 790-101-5061 • Plate t 1
• 790-101-5021 • Grip t 1
PC750, 800-7 30-29

(2)
3) Disassemble No. 3 carrier assembly as fol- 5. No. 3 sun gear

lows. 1) Remove thrust washer (11) from No. 3 sun
i) Remove mounting bolts (3). gear (10).
ii) Using tool J5, remove holder (4). 2) Remove No. 3 sun gear (10).
iii) Turn over carrier assembly (2) and set 6. No. 3 ring gear
to press, then using tool J6, pull out Using eyebolts , remove No. 3 ring gear (12).
shaft (5) and remove gear assembly (6).
7. Hub assembly
iv) Remove bearing (7) and spacer (8) from 1) Remove lock plate (13).
gear (6). 2) Using tool J4, remove nut (14).
a If the parts are to be used again,
make match marks to prevent any
change in the combination with the
outer race.
v) Remove outer race (9) from gear (6).
30-30 PC750, 800-7

(2)
3) Using eyebolts , remove hub assembly iii) Pull out gear (23) from carrier (27), and
(15) together with bearing (16) from shaft remove thrust washer (24) and bearing
(41). (25).
4) Remove bearing (16) from hub (49). iv) Remove thrust assembly (26) from car-
rier (27).
5) Remove floating seal (17) from hub (49).

a If the seal is to be used again, be careful not 10. No. 2 sun gear
to damage the contact surface, and keep in Remove No. 2 sun gear (28).
a safe place.
6) Remove outer races (18). 11. No. 2 ring gear
Remove No. 2 ring gear (30).
8. Spacer
Remove spacer (19) from shaft (41). 12. Spacer
Remove spacer (31).
9. No. 2 carrier assembly

1) Using eyebolts , remove No. 2 carrier
assembly (20).
2) Disassemble No. 2 carrier assembly as fol-
lows.
i) Knock pin (21) into shaft (22).
ii) Push shaft (22) from pin side to remove.
a Remove the pin from the shaft.
PC750, 800-7 30-31

(2)
13. No. 1 carrier assembly 14. No. 1 ring gear

1) Using eyebolts , remove No. 1 carrier Remove No. 1 ring gear (39).
assembly (32).
2) Disassemble No. 1 carrier assembly as fol- 15. No. 1 sun gear
lows. Remove No. 1 sun gear (40).
i) Knock pin (33) into shaft (34). a However, if the travel motor is removed, the
ii) Remove shaft (34) from pin end. sun gear will fall off when it is put in the pos-
a Remove the pin from the shaft. ture for disassembly.
16. Thrust washer

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

Remove floating seal (17).
a If the seal is to be used again, be careful not
to damage the contact surface, and keep in
a safe place.
iii) Pull out gear (35) from carrier (36), then

remove thrust washer (37) and bearing
(38).
18. Travel motor assembly

Turn over shaft (41), and using eyebolts ,
remove travel motor assembly (42).
30-32 PC750, 800-7

(2)
ASSEMBLY 5. No. 1 carrier assembly

a 1) Clean all parts, check for dirt or damage, and 1) Assemble No. 1 carrier assembly as follows.
correct all dents and burrs. a There are the remains of the caulking
2) Coat the bearings and surfaces of all parts when the pin is inserted at the end face
with engine oil before installing. of hole h at the side of the carrier, so re-
move the caulked metal from the inside
1. Travel motor assembly diameter of the hole before starting to
1) Fit O-ring, and using eyebolts , install assemble.
travel motor assembly (42) to shaft (41). i) Assemble bearing (38) to gear (35), put
a The mounting direction for the motor on thrust washer (37) in contact with both
the left and right final drive assemblies is ends, then set to carrier (36).
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}
ii) Align position of pin holes of carrier and

shaft, then tap with a plastic hammer to
install shaft (34).
a When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
iii) Install pin (33).
a Check that the pin groove and pro-
truding part of the pin are not fa-
2. No. 1 sun gear tigued. If the pin is defective, replace
Install No. 1 sun gear (40). it with a new part.
a When assembling the pin again,
3. No. 1 ring gear avoid the position previously used
Install No. 1 ring gear (39). for caulking.
a Set with the side with the cut outside circum- a After inserting the pin, caulk the pin
ference facing the motor. portion (marked by arrows) of the
carrier.
4. Spacer a After assembling the carrier assem-
Install spacer (31). bly, check that gear (35) rotates
smoothly.
PC750, 800-7 30-33

(2)
2) Using eyebolts , install No. 1 carrier a There are the remains of the caulking
assembly (32). when the pin is inserted at the end face
of hole h at the side of the carrier, so re-
move the caulked metal from the inside
diameter of the hole before starting to
assemble.
iii) Assemble bearing (25) to gear (23), put
thrust washer (24) in contact with both
ends, then set to carrier (27).
iv) Align position of pin holes of carrier and
shaft, then tap with a plastic hammer to
install shaft (22).
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).
v) Install pin (21).

a 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.
a When assembling the pin again,
avoid the position previously used
8. No. 2 carrier assembly for caulking.
1) Assemble No. 2 carrier assembly as follows. a After inserting the pin, caulk the pin
i) Press fit thrust washer (44) to plate (43). portion (marked by arrows) of the
ii) Press fit thrust assembly (26) to carrier carrier. (See Step 5-1)-iii).)
(27). a After assembling the carrier assem-
bly, check that gear (33) rotates
smoothly.
2) Using eyebolts , install No. 2 carrier
assembly (20).
30-34 PC750, 800-7

(2)
9. Spacer 2) Inside bearing

Align protruding portion with protruding portion Shrink fit bearing (16) to shaft (41), or use
of shaft (41), and install spacer (19). tool J3 to install.
a Set the spacer with the shallow protruding
part facing the motor.
10. Hub assembly

1) Floating seal at shaft end
Using tool J1, install floating seal (17) to
shaft (41).
a Remove all oil and grease from the O-
ring and O-ring contact surface, and dry
the parts before installing the floating
seal.
a After installing the floating seal, check
that the angle of the floating seal is with-
in 1 mm. a When using tool J3, see the drawing below.
a After installing the floating seal, coat the
sliding surface thinly with engine oil.
3) Outer race at hub end

Expand fit outer race (18) to hub (49), or use
tool J2 to install.
a When using tool J2, see the drawing be-
low.
PC750, 800-7 30-35

(2)
4) Floating seal at hub end 7) Install nut as follows.

Using tool J1, install floating seal (17) to hub i) Set tool J3 in position.
(49). ii) Push bearing inner race portion with
a For precautions and details of the tool, specified force.
see Step 10-1). a Pushing force:
a When turning over the hub, the floating 34.3 – 38.2 kN {3.5 – 3.9 ton}
seal will be at the bottom, so install it iii) Rotate hub assembly 2 – 3 times to set-
temporarily with several bolts . tle bearing.
5) Installation of hub assembly
Using eyebolts , install hub assembly (15)
to shaft (41).
iv) Measure dimension a in the condition

above.
6) Outside bearing
Install bearing (16).
v) Measure thickness b of nut (14) as an

individual part.
vi) Calculate a – b = c.
vii) Using tool J4, tighten nut (14) to a point
0
where dimension c = –0.1 mm.
30-36 PC750, 800-7

(2)
8) Install lock plate (13). ii) Assemble bearing (7) and spacer (8) to
a Install the lock plate as shown in the dia- gear (46), and set to carrier (47).
2 Thread of mounting bolt:

gram below. a Align the carrier and bearing and
spacer holes securely.
3 Mounting bolt:
Thread tightener (LT-2)
66.2 ± 7.3 Nm {6.75 ± 0.75 kgm}
iii) Expand fit shaft (5) or press fit with a

press.
a Do not move the gear until the tip of
11. No. 3 ring gear shaft (5) enters the carrier. Be par-
1) Install O-ring to shaft end. ticularly careful with the spacer.
2) Using eyebolts , install No. 3 ring gear a After press fitting the pin, check that
(12). the gear rotates smoothly.
a Align the bolt holes. a When press fitting the shaft, be
a Install the ring gear with the machined careful of the angle of the shaft.
outside circumference facing up (out- iv) Assemble holder (4) to shaft (5).
side).
2 Bolt: Thread tightener (LT-2)

v) Tighten bolt (3).
3 Bolt:
12. No. 3 carrier assembly
1) Assemble No. 3 carrier assembly as follows.
i) Using tool J7, press fit outer race (9) to 927 ± 103 Nm {94.5 ± 10.5 kgm}
gear (46). vi) Install thrust washer (50).
PC750, 800-7 30-37

(2)
2) Using eyebolts , install No. 3 carrier

assembly (2).
a Align the low portion (4 places) of spacer
(19) and shaft (41) with the carrier as-
sembly holder.
a Align the bolt holes also.
13. No. 3 sun gear

1) Install thrust washer (11) to No. 3 sun gear
(10).
2) Install No. 3 sun gear (10).
a Be careful not to get your fingers caught.
14. Cover
2 Mounting surface:
Using eyebolts , install cover (1).
2 Bolt: Thread tightener (LT-2)

Gasket sealant (LG-6)
3 Bolt: 980.1 ± 49.5 Nm {100 ± 5 kgm}
30-38 PC750, 800-7

(2)

J3 Push tool
PC750, 800-7 30-39

(2)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL AND INSTALLATION OF REVOLVING FRAME

ASSEMBLY
REMOVAL 6. Pull out pin (7), and move link (8) towards frame.
1. Remove work equipment assembly from chas-
sis.
For details, see REMOVAL OF WORK EQUIP-
MENT ASSEMBLY.
2. Remove counterweight assembly.

For details, see REMOVAL OF COUNTER-
WEIGHT 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. 7. Revolving frame assembly
a Start the engine and swing the revolving 1) Fit wires to counterweight mounting frame
frame while removing the bolts. and boom mount, then sling revolving frame
a If you do not start the engine, remove the assembly.
swing motor and use a crane to swing the re- 2) Remove remaining mounting bolts and lift
volving frame. off revolving frame assembly (9).
a Check that the wire is not damaged before
using it, and put protective material at the
corners.
a The revolving frame will tilt towards the oper-
ator’s cab, so adjust with a lever block.
4 Revolving frame assembly:

Approx. 19,000 kg
5. Disconnect swivel joint top pipes (3), (4), (5),

and (6).
INSTALLATION
• Carry out installation in the reverse order to
removal.
2 Mounting bolt: Thread tightener (LT-2)

3 Mounting bolt:
1,814 ± 98 Nm {185 ± 10 kgm}
2 Swing circle top surface:

30-40 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
REMOVAL AND INSTALLATION OF SWING MACHINERY

ASSEMBLY
1. Remove the swing motor assembly (1) referring • To install this assembly, reverse the removing
3 Mounting bolt:
to the paragraph of "Removal of Swing Motor procedures.
Assembly".
926.7 ± 102.9 Nm {94.5 ± 10.5 kgm}
• Oil Filling
filler port.
5 Oil amount in swing machinery

case: Approx. 30 l x 2
2. Drain oil from the swing machinery.
6 Oil in case: Approx. 24.5 l x 2
3. Lift the swing machinery assembly (2) 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 x 2
PC750, 800-7 30-41

(2)
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY

ASSEMBLY
SPECIAL TOOLS 3. No. 1 carrier assembly
1) Remove thrust washer (2).
New/Remodel
2) Remove No. 1 sun gear (3).
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
3 2
790-101-5401 Push tool kit t 1

• 790-101-5541 • Plate t 1
1
• 790-101-5421 • Grip t 1
F • 01010-81240 • Bolt t 1
790-201-2780 Spacer t 1 CEP00206
2
790-201-2880 Spacer t 1
3) Remove No. 1 carrier assembly (4).
3 796T-626-1130 Push tool t 1 N Q
4
DISASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing
machinery case.
6 Swing machinery case: Approx. 24.3 l
2. Cover CEP00207
Remove mounting bolts, then lift off cover (1).

4. Disassemble No. 1 carrier assembly as follows.
1) Push in pin (5) and knock out shaft (6) from
carrier (7).
1 a After removing the shaft, remove pin (5).
2) Remove thrust washer (8), gear (9), bearing
(10), and thrust washer (11).
CEP00205
30-42 PC750, 800-7

(2)
5. Ring gear 7. No. 2 carrier assembly

Lift the ring gear (12) and remove it. Lift No. 2 carrier assembly (17) and remove it.
6. No. 1 sun gear 8. Disassemble No. 2 carrier assembly as follows.

1) Remove the thrust washer (13). 1) Push in pin (18), and knock out shaft (19)
2) Remove the button (36) and the spacer from carrier (17).
(14). a After removing the shaft, remove pin
3) Remove No. 1 sun gear (15). (18).
2) Remove thrust washer (20), gear (21), bear-
ing (22), and thrust washer (23).
19 22 17
20
21
23
18
CEP00213
4) Remove the thrust washer (16).
a Remove No. 2 carrier assembly (17) be-
fore removing the washer. 9. Pinion shaft assembly
1) Remove bolt (24), then remove holder (25).
2) Remove gear (26).
24
26
25
CEP00214
PC750, 800-7 30-43

(2)
3) Turn over case and pinion assembly, then 11. Bearing

remove mounting bolts (28) of cover assem- Using push tool, remove bearing (34) from case
bly (27). (35).
35 34
27
28
CEP00215 CEP00220
4) Turn over case and pinion assembly (29), ASSEMBLY

and set on press stand, then using push tool a Clean all parts, and check for dirt or damage.
F3, remove pinion shaft assembly (30) with Coat the sliding surfaces of all parts with engine
press. oil before installing.
a Set a wooden block under the press, and
be careful not to damage the pinion shaft 1. Bearing
assembly when removing it. Using push tool F2, press fit bearing (31) to
case (35).
10. Disassemble pinion shaft assembly as follows.

1) Using push tool , remove cover assembly 2. Cover assembly
(27) and bearing (31) from shaft (32). 1) Using push tool F1, press fit oil seal (33) to
2 Outside circumference of oil seal:

2) Remove oil seal (33) from cover (27). cover (27).

33 a Be careful not to let the gasket sealant
(LG-6) get on the oil seal lip when press
fitting.
27
31
32
27
CEP00218 CEP00219
30-44 PC750, 800-7

(2)
2) Fit cover assembly (27) to case (35), and 2) Bearing
2 Cover mounting surface:

tighten mounting bolts (28). Using tool F3, press fit bearing (34).
a Push the bearing inner race and outer
2 Lip of oil seal: Grease (G2-LI)

Gasket sealant (LG-6) race at the same time when press fitting.
Do not push only the inner race when
a Be careful not to let the gasket sealant press fitting.
(LG-6) get on the oil seal lip when press a After press fitting the bearing, check that
fitting. the case rotates smoothly.
27 28
35
CEP00223
3. Case assembly 3) Gear, holder

1) Set case assembly (35) to shaft (32), then Assemble gear (26), then fit holder (25) and
2 Mounting bolt:
using push tool , press fit bearing inner tighten bolt (24).
race portion.
3 Mounting bolt:
a When setting the case assembly to the Thread tightener (LT-2)
shaft, be extremely careful not to dam-
age the oil seal. 385 ± 42 Nm {39.25 ± 4.25 kgm}
24
26
25
CEP00214
PC750, 800-7 30-45

(2)
4. Assemble No. 2 carrier assembly as follows. 5. No. 2 carrier assembly

a There are the remains of the caulking when Lift No. 2 carrier assembly (17) and install it.
the pin is inserted at the end face of hole h at a Adjust the positions of the 4 gear shaft ends
the side of the carrier, so remove the caulked before installing it.
metal from the inside diameter of the hole
before starting to assemble.
1) Assemble bearing (22) to gear (21), fit top
and bottom thrust washers (23) and (20)
and set gear assembly to carrier (17).
22 17
20
21
23
6. No. 2 sun gear
1) Set the thrust washer (16).
h a Be sure to set the washer before installing
CEP00226
No. 2 carrier assembly (17).
2) Align position of pin holes of shaft and car-

rier, then tap with a plastic hammer to install
shaft (19).
3) Insert pin (18).
a After inserting the pin, caulk the pin por-
tion of the carrier.
a After assembling the carrier assembly,
check that gear (21) rotates smoothly.
21 19 2) Assemble No. 2 sun gear in No. 2 carrier.

3) Install the spacer (14) and the button (36).
4) Install the thrust washer (13).
18
CEP00227
30-46 PC750, 800-7

(2)
7. Ring gear 2) Align position of pin holes of shaft and car-

Lift the ring gear (12) and install it. rier, then tap with a plastic hammer to install
a Apply gasket sealant to the periphery of the shaft (6).
2 Mating face of ring gear and case:

oil level check hole only. a When installing the shaft, rotate the
Gasket sealant (LG-6) damage the thrust washer.
3) Insert pin (5).
a After inserting the pin, caulk the pin por-
tion of the carrier.
a After assembling the carrier assembly,
check that gear (9) rotates smoothly.
8. Assemble No. 1 carrier assembly as follows.

a There are the remains of the caulking when
the pin is inserted at the end face of hole h at
the side of the carrier, so remove the caulked
metal from the inside diameter of the hole
before starting to assemble. 9. No. 1 carrier assembly
1) Assemble bearing (10) to gear (9), fit top Install No. 1 carrier assembly (4).
and bottom thrust washers (8) and (11) and
set gear assembly to carrier (7). 4
CEP00207
10. No. 1 sun gear

1) Assemble No.1 sun gear (3) to carrier
assembly.
2) Install thrust washer (2).
3 2
CEP00206
PC750, 800-7 30-47

(2)
11. Cover
2 Cover mounting surface:

Install cover (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 l

F3 Push tool
30-48 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY

1. Remove revolving frame assembly. • Carry out installation in the reverse order to
For details, see REMOVAL OF REVOLVING removal.
FRAME ASSEMBLY.
2. Remove grease tubes (1). 2 Mounting bolt: Thread tightener (LT-2)

3 Mounting bolt:
3. Remove mounting bolts (2). 1,715 ± 195 Nm {175 ± 20 kgm}
2 Swing circle mounting surface:

a Amount of grease (G2-LI) in oil bath:
Approx. 65 l
a Coat inside teeth with grease (G2-LI).
a Apply about 10 l of grease (G2-LI) to the in-
ternal tooth.
a Install so that the inner race soft zone is fac-
ing the left side of the chassis.
4. Pass round bar through revolving frame mount-

ing bolt holes, fit wire, then lift off swing circle
assembly (3).
4 Swing circle assembly: 1,263 kg
5. Remove seal (4).
PC750, 800-7 30-49

(2)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY

SPECIAL TOOLS 3. Using tool M, pull out master pin.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
Remover,
791-680-9501 t 1
installer
Cylinder (1,471
790-101-4300 t 1
1 kN {150 ton})
M Puller (294 kN
790-101-4200 t
{30 ton})
790-101-1102 Pump t 4. Fit block or hydraulic jack (10 ton) under shoe
at idler end, then remove guide pin .
2 790-331-1100 Wrench t
REMOVAL
1. Positioning master pin
a Move the master pin so that it is midway be-
tween the idler and the carrier roller. The
track shoe is opened to the rear, so be sure
that there is enough space.
2. Loosen track shoe tension.

k Never loosen lubricator (1) more than one
turn.
a If the track tension is not relieved even when 5. Raise tip of track shoe with crane, and move
the lubricator is loosened, move the machine machine slowly to rear to open track shoe
backwards and forwards. assembly (3).
30-50 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
INSTALLATION
removal.
a Adjust the track shoe tension.

For details, see TESTING AND ADJUST-
3 Lubricator:
ING, Adjusting track shoe tension.
73.5 ± 14.7 Nm {7.5 ± 1.5 kgm}
a Assemble spacer (4) and washer (5) to the

link, connect to bottom link, then install guide
pin.
PC750, 800-7 30-51

(2)
DISASSEMBLY AND ASSEMBLY ONE LINK IN FIELD
DISASSEMBLY AND ASSEMBLY OF ONE LINK IN FIELD

SPECIAL TOOLS
New/Remodel
New/Remodel
Symbol
Symbol
Sketch
Sketch
Necessity
Necessity
Q’ty
Q’ty
Part No. Part Name Part No. Part Name
791-680-9580 Adapter t 1 5 790-101-4300 Cylinder (*1) t 1

791-680-9590 Guide t 1 790-101-1102 Pump t 1
1 6
01010-52760 Bolt t 2 790-101-4200 Pulley (*2) t 1
01010-51440 Bolt t 2 791-680-5542 Adapter t 1
7
790-101-1102 Pump t 1 791-632-1110 Adapter t 1
2
790-101-4300 Cylinder (*1) t 1 8 791-680-5580 Guide t 1
791-685-9510 Frame t 1 791-685-9510 Frame t 1
791-685-9520 Frame t 1 791-685-9520 Frame t 1
791-685-9530 Rod t 1 791-685-9530 Rod t 1
791-685-9550 Nut t 1 791-685-9540 Rod t 1
791-685-9560 Bolt t 4 791-685-9550 Nut t 3
3
791-680-9570 Adapter t 1 791-685-9560 Bolt t 4
01010-51030 Bolt t 1 9 791-126-0150 Adapter t 1
04530-12030 Eyebolt t 1 01010-51030 Bolt t 1
790-101-1102 Pump t 1 791-685-9620 Extension t 1
N 790-101-4300 Cylinder (*1) t 1 N 791-680-5542 Adapter t 1
791-685-9540 Rod t 1 791-680-5560 Guide t 1
4
791-685-9550 Nut t 3 790-101-1102 Pump t 1
791-685-9510 Frame t 1 790-101-4300 Cylinder (*1) t
791-685-9520 Frame t 1 791-685-9510 Frame t 1
791-685-9530 Rod t 1 791-685-9520 Frame t 1
791-685-9550 Nut t 1 791-685-9530 Rod t 1
791-685-9560 Bolt t 4 791-685-9540 Rod t 1
791-126-0150 Adapter t 1 791-685-9550 Nut t 3
5 791-680-5520 Guide t 1 791-685-9560 Bolt t 4
10
791-126-0140 Pusher t 1 791-126-0150 Adapter t 1
791-680-9570 Adapter t 1 01010-51030 Bolt t 1
01010-51030 Bolt t 1 791-685-9620 Extension t 1
04530-12030 Eyebolt t 1 791-680-5560 Guide t 1
791-685-9620 Extension t 1 791-632-1110 Adapter t 1
791-101-1102 Pump t 1 791-680-9630 Adapter t 1
30-52 PC750, 800-7

(2)
DISASSEMBLY
1. Using two bolts (2), install tool N1 (adapter,
New/Remodel
guide, bolt) to link (1).
a It is also possible to use two track bolts for
Symbol
Sketch
Necessity
Q’ty
Part No. Part Name bolt (2).
790-101-1102 Pump t 1
10
790-101-4300 Cylinder (*1) t 1
11 790-680-1520 Guide t 1
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 3 2. Assemble tool N2 (pump, cylinder 1471 kN
{150t}) and tool N3 (frame, rod, adapter, bolt x 1,
791-685-9560 Bolt t 4 eyebolt), then raise chassis and set on track.
12 791-126-0150 Adapter t 1
791-680-5560 Guide t 1
N
791-680-9570 Adapter t 1
01010-51030 Bolt t 1
791-680-1520 Guide t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder (*1) t 1
790-101-1102 Pump t 1
13
790-101-4200 Pulley (*2) t 1 3. Insert rod of tool N4 from cylinder end, and
Remover (kit), install with two nuts.
791-680-9501 t 1 a Pass the rod through the hole in link (1) to in-
installer
stall.
790-101-1102 Pump t 1
14
790-101-4200 Pulley (*2) t 1
790-101-4300 Cylinder (*1) t 1
(*1) : 1,471 kN {150 ton}

(*2) : 294 kN {30 ton}
PC750, 800-7 30-53

(2)
4. Set tool N5 (adapter, guide, pusher) in position, ASSEMBLY

then apply hydraulic pressure and remove pin 1. Assemble link sub-assembly.
(3). 1) Set tool N7 to end face of link, then press fit
When the cylinder reaches the end of its stroke, bushing (1).
insert extension N5 between the adapter and 2) Set tool N7 to end face of link (pin end), and
guide, and repeat the operation. press fit pin (2).
5. Set tool N6 (294 kN {30 ton} puller) and spacer 2. Set link sub-assembly (3) on link to be con-
to center of roller tread of link to be disassem- nected.
bled, then apply hydraulic pressure to puller and
open link 5 – 6 mm.
3. Set link (4) on opposite side, and support with

tool N8 (guide).
30-54 PC750, 800-7

(2)
4. Set tools N9 and N10 in same way as for opera- 7. Set tool N9 at pin (7) end, then use tool N12
tion to remove pin, then use tool N9 (adapter, (adapter, bolt, and guide) to press fit pin (7).
2 Pin press-fitting hole in link:

extension, guide, adapter, bolt) for press fitting
pin, and tool N10 (extension, guide, adapter,
bolt) for press fitting bushing, and press fit in Gasket sealant (LG-1)
turn.
5. Use tool N13 (294 kN {30t} puller) in same way

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

connect with tool N11 (guide), then remove tool
N13 (puller).
PC750, 800-7 30-55

(2)
DISASSEMBLY AND ASSEMBLY IDLER
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY

REMOVAL
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Remove idler assembly (1).

a Pull out the idler assembly, then lift off the
idler and adjustment cylinder.
4 Idler assembly: 500 kg
INSTALLATION
removal.
30-56 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY

SPECIAL TOOLS 5. Remove shaft (8) from idler.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
1 790-201-2680 Plate t 1
L
2 796-675-1510 Instaler t 1
DISASSEMBLY
1. Remove plug and drain oil.
6. Remove floating seal (4) from idler (7).
6 Idler : Approx. 550 – 630 cc
2. Set idler assembly (1) on block , remove bolt

and nut (2), then remove support (3).
3. Remove floating seal (4).
7. Remove bushings (9) and (10) from idler.
4. Turn over idler assembly, remove bolt and nut

(5), then remove support (6).
PC750, 800-7 30-57

(2)
8. Remove floating seals (4) from supports (3) and ASSEMBLY

(6). a Clean all parts, and check for dirt or damage.
1. Using tool L2, assemble floating seals (4) to

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

idler.
3. Using tool L2, assemble floating seal (4) to idler.
30-58 PC750, 800-7

(2)
4. Turn over idler and using tool L2, assemble 8. Turn over idler, and assemble support (3) to
floating seal (4). shaft.
a Align the groove in the support with the
groove in the shaft when assembling.
9. Install bolt and nut (2), and secure support (3).
5. Install shaft (8) to idler.

a Assemble the shaft so that the direction of
the oil filler plug is as follows.
• Right side of machine: Facing outside
• Left side of machine: Facing inside 10. Using tool, add oil to specified level, then tighten
plug.
5
3 Plug: 210.7 ± 29.4 Nm {21.5 ± 3 kgm}
Idler: 550 – 630 cc (GO140B)
6. Assemble support (6) to shaft.

a Align the groove in the support with the
groove in the shaft when assembling.
7. Install bolt and nut (5), and secure support (6).
PC750, 800-7 30-59

(2)
DISASSEMBLY AND ASSEMBLY IDLER ADJUSTMENT CYLINDER
DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT

CYLINDER ASSEMBLY
DISASSEMBLY ASSEMBLY
1. Remove plunger assembly (1). 1. Install wear ring (6) to plunger (2).
2. Remove snap ring (3), then remove packing (4), 2. Assemble backup ring (5) and packing (4) to
backup ring (5), and wear ring (6) from plunger plunger (2), and install snap ring (3).
(2).
3. Fill inside with grease (G2-LI), then assemble
3. Remove dust seal (7). plunger assembly (1) in piston.
4. Install dust seal (7).
30-60 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY
a The coil portion of the recoil spring assembly is • Carry out installation in the reverse order to
hooked on the rib inside the track frame, so pre- removal.
pare a special tool for disassembly. a To check that the spring is securely fitted in-
side the track frame, check through the side
1. Remove track shoe assembly. hole on the inside (at the 5th track roller from
For details, see REMOVAL OF TRACK SHOE the front).
ASSEMBLY.
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 REMO VAL OF
TRACK ROLLER ASSEMBLY.
2) After removing track roller assembly, install
tool .
a When making tool , see Fig. 1.
a Lower the track frame on top of the track
shoe.
3) Using eyebolts (Thread dia. = 16 mm, Pitch
= 2.0 mm), pull out recoil spring assembly
(1) and lift off.
4 Recoil spring assembly: 250 kg
PC750, 800-7 30-61

(2)
Fig. 1 (for tool )
30-62 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY

SPECIAL TOOLS 2. Apply hydraulic pressure slowly to compress
spring, then remove lock plate, and remove nut
New/Remodel
(2).
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
791-685-8501 Compressor t 1
791-635-3160 Extension t 1
796-630-1110 Plate t 1
01010-51640 Bolt t 2
M 3
791-630-1120 Spacer t 1
Cylinder (686
790-101-1600 t 1
kN {70 ton}) 3. Release hydraulic pressure gradually to relieve
790-010-1102 Pump t 1 tension of spring, then remove recoil spring
assembly (1) from tool M3.
796-630-1110 Plate t 1
4. Remove rear pilot (4) and rod (5) from spring
(3).
DISASSEMBLY
1. Set recoil spring assembly (1) to tool M3.
k The recoil spring is under large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.
a Installed load of spring: 490 kN {50 ton}
PC750, 800-7 30-63

(2)
ASSEMBLY
1. Install tool D1 to tip of rod (5).
a Tool M3 is to prevent damage to the thread
when inserting the rear pilot.
2. Install rod (5) to spring (3).

Assemble rear pilot (4), and set to tool M3.
k The recoil spring is under large installed
load, so be sure to set the parts properly.
Failure to do this is dangerous.
3. Apply hydraulic pressure slowly to compress

spring so that installed length of spring is stan-
dard dimension.
a Installed length "a" of spring: 1,290 mm
4. Fit nut (2) and secure with lock plate.
5. Release hydraulic pressure gradually to relieve

tension of spring, then remove recoil spring
assembly (1) from tool M3.
30-64 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY
1. Loosen the track shoe a bit referring to the para- • To install this assembly, reverse the removing
3 Carrier roller mounting bolt:

graph of "Tension Adjustment of Track Shoe" in procedures.
Testing and Adjusting.
549 ± 58 Nm {56 ± 6 kgm}
2. Use the hydraulic jack 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.

a Take out the carrier roller assembly as far as
it does not drop.
4 Carrier roller assembly: 52 kg
PC750, 800-7 30-65

(2)
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER

ASSEMBLY
SPECIAL TOOLS 5. Remove the assembly of the roller (4) and the
floating seal (5) on the support (2).
New/Remodel
Necessity
6. Remove the floating seal (5) from the support
Symbol
Sketch
Q’ty
Part No. Part Name (2).
7. Remove the bearing (6) from the support (2).

3 790-1101-5401 Push tool kit t 1
4 796T-630-1130 Push tool t 1
L
5 796T-630-1140 Adapter t 1 N Q
6 791-670-1010 Installer t 1
DISASSEMBLY
1. Remove the plug and drain oil.
6 Carrier roller assembly:

Approx. 300 – 350cc 8. Remove the floating seal (5) from the roller (4).
2. Set the carrier roller assembly (1) on the press 9. Remove the bearing (6) from the shaft (3) by
base. using the tool L3.
a 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 be-
low the roller.
3. Push the shaft end face with the press and

install the assembly of the support (2), the shaft
(3) and the roller (4).
a Remove the floating seal (5) from the 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). 10. Remove the bearing outer race (7) from the sup-
port (2).
30-66 PC750, 800-7

(2)
ASSEMBLY 10. Press fit the roller, in which the floating seal (5)
1. Press fit the bearing outer race (7) in the both was assembled, in the shaft (3).
sides of the support (2) by using the tool L3. a Press fit the roller (4) to the shaft end face
and press fit the roller finally by using the tool
2. Press fit the bearing (6) in the shaft (3) by using L5.
the tool L3. a Secure more than 18 ton of press fitting force
between the shaft and each roller.
3. Mount the floating seal (5) on the roller (4) by

using the tool L4. 11. Assemble the carrier roller assembly (1) and fill
a Make sure that the seal is inclined less than it with oil.
5
1 mm.
a Clean the O-ring and the O-ring contacting Lubricating oil: 300 – 350cc (GO140)
surface to degrease them completely and
3 Plug: 206 ± 49 Nm {21 ± 5 kgm}

dry them. 12. After filling it with oil, plug the assembly.
4. Set the roller (4), on which the floating seal (5)

was set, on the tool L5.
5. Press fit the shaft (3), to which the bearing (6)

was assembled, in the roller (4).
6. Assemble the floating seal (5) in the support (2)

and mount them so that the bearing (6) aligns to
the bearing outer race (7).
7. Insert the spacer (8) in the shaft.
8. Press fit the bearing (6) in the shaft (3).
9. Mount the floating seal (5) on the support (2).
PC750, 800-7 30-67

(2)

L-5 Adapter
30-68 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY

SPECIAL TOOLS 4. Using tool L7, remove track roller assembly (2).
New/Remodel
Track roller assembly (S flange):
Necessity
140 kg
Symbol
Sketch
Q’ty
Part No. Part Name
791-401-1700 Lifting tool t 1

791-401-1761 Adapter t 1
L 7
791-401-1540 Shackle t 2
791-401-1770 T-bolt t 2
REMOVAL
1. Loosen track shoe tension.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY. INSTALLATION
2. Remove track roller guard (1). removal.
4 Track roller guard: 170 kg 3 Roller mounting bolt:

137.2 ± 98 Nm {140 ± 10 kgm}
3. Using work equipment, push up track frame on

side which is to be removed.
k After jacking up the chassis, set a block on
the track shoe.
PC750, 800-7 30-69

(2)
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY

SPECIAL TOOLS 4. Pull out roller (4) from shaft (5).
a It is filled with 280 – 310 cc. of oil, so drain
New/Remodel
the oil at this point or lay a cloth to prevent
Necessity
the area from becoming dirty.
Symbol
Sketch
Q’ty
Part No. Part Name
5. Remove floating seal (6) on opposite side from
roller (4) and collar (8).
8 791-580-1520 Installer t 1
9 790-201-2670 Plate t 1 5
6
791-601-1000 Oil pump t 1
L
or 4
10 4
791-646-8002 Oil lubricator t 1
790-701-3000 Seal checker t 1
CEP00087 CEP00088
DISASSEMBLY
1. Remove plug and drain oil.
6. Remove pin (7), then remove collar (8) from
a Rotate the shaft while draining the oil.
shaft (5).
6 Track roller: Approx. 420 – 480 cc
7. Remove bushings (9) and (10) from roller (4).
2. Remove pin (1), then remove collar (2).
9, 10
5
4
7 CEP00089 CEP00090
3. Remove floating seal (3) from collar (2) and

roller (4).
3
1
2 CEP00085 CEP00086
30-70 PC750, 800-7

(2)
ASSEMBLY 4. Using tool L9, install floating seals (6) and (3) to
1. Using tool L10, press fit bushings (9) and (10) to roller (4).
roller (4). a For details of the precautions when installing
floating seals (6b) and (6d), and (3b) and
2. Assemble collar (8) to shaft (5), and install pin (3d), see the precautions marked a for Step
(7). 3.
3. Using tool L9, install floating seal (6) to shaft (5). 5. Assemble shaft (5) to roller (4).
CEP00096
a When assembling the floating seal, clean the 6. Turn over roller (4) and shaft (5) assembly.
contact surface of O-ring (6c) and floating
seal (6a), remove all grease and oil, and dry 7. Using tool L9, install floating seal (3) to collar
it. Make sure that no dirt or dust sticks to the (2).
contact surface of the floating seal. a For details of the precautions when installing
a After inserting the floating seal, check that floating seals (3a) and (3c), see the precau-
the angle of the seal is less than 1 mm and tions marked a for Step 3.
that the protrusion of the seal is within a
range of 5 – 7 mm.
CEP00097
8. Assemble collar (2) to shaft (5), and install pin

(1).
1
2
5
CEP00099
PC750, 800-7 30-71

(2)
9. Using tool L10, apply standard pressure to roller

oil filler port, and check for leakage of air from
seal.
a Standard pressure: 0.1 MPa {1 kg/cm2}
a Method of checking
The standard pressure shall be maintained
for 10 seconds and the indicator of the
gauge shall not go down.
10. Using tool L10, fill track roller assembly with oil,
then tighten plug (11).
5 Track roller oil:
3 Plug: 14.7 ± 4.9 Nm {1.5 ± 0.5 kgm}

280 – 310 cc (EO30-CD)
11
CEP00202
30-72 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY

REMOVAL 4. Remove 3 pieces of the wiring clamp (3) and
k Swing the frame to bring the hydraulic tank to the disconnect the wiring connector (4).
intermediate position between the left and the
right track shoes.
a Place counter marks on all hoses before discon-
necting them.
a Stop all disconnected tubes and hoses with plug.
1. Drain oil from the hydraulic tank.
6 Hydraulic tank : 650 l

5. Loosen 3 pieces of the mounting bolt (5) of the
2. Remove the control valve cover (1). pilot relief valve assembly and remove the valve
assembly from the hydraulic tank without dis-
connecting the hose.
6. Loosen the drain filter assembly bracket bolt (6)

and remove it from the hydraulic tank.
7. Loosen the PTO lubricating oil filter bracket bolt

(7) and remove it from the hydraulic tank.
PC750, 800-7 30-73

(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
8. Disconnect the return filter inlet hose (8) and the 12. Lift the hydraulic tank assembly (14) and
outlet hose (9) from the control valve. remove it.
4 Hydraulic tank assembly: 474 kg
9. Disconnect the hose (10) from the oil cooler.
10. Disconnect the hoses (11) and (12) from the

return filter to the oil cooler. INSTALLATION

procedures.
3 Hydraulic tank mounting bolt:

549 ± 58 Nm {56 ± 6 kgm}
• Filling (hydraulic tank) with oil

Circulate oil throughout the pipe and then check
the oil level again.
• Air Bleeding
Bleed air referring to the paragraph of "Bleeding
Air from Each Part" in Testing and Adjusting.
11. Disconnect the suction tube (13) below the
hydraulic tank.
30-74 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY MAIN PUMP (NO. 1 PUMP)
REMOVAL AND INSTALLATION OF MAIN PUMP (NO. 1 PUMP)

ASSEMBLY
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
1 796-770-1301 Oil stopper t 1

2 209-60-71130 Rod assembly t 1
3 790-101-5001 Push tool kit t 1
L
4 • 790-101-5151 • Plate t 1
5 • 790-101-5021 • Grip t 1
6 01010-50816 Bolt t 1
REMOVAL
k Disconnect the (–) terminal of the battery.
a 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 7. Disconnect the hoses (9), (10), (11), (13) and
stop oil flow by using the tool S. (14).
a When the tool S is not used, remove the
drain plug and drain oil from the hydraulic 8. Disconnect the suction tube (12).
tank and the pipes.
6 Hydraulic tank: Approx. 500 l
2. Open the engine hood and the pump rear cover

and remove the pump upper cover.
3. Remove the TVC solenoid connector (1).
4. Disconnect the hose (2).
PC750, 800-7 30-75

(2)
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
INSTALLATION
procedures.
• Filling (the hydraulic tank) with oil

filler port, start the engine to circulate oil
throughout the pipes and check the oil level
again.
• Bleeding Air
a Bleed air from each part referring to the par-
agraph of "Testing and Adjusting".
30-76 PC750, 800-7

(2)
REMOVAL AND INSTALLATION OF MAIN PUMP (NO. 2 PUMP)

SPECIAL TOOLS 3. Separate the hoses (1), (2), (3) and (4).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
1 796-770-1301 Oil stopper t 1

2 209-60-71130 Rod assembly t 1
3 790-101-5001 Push tool kit t 1
L
4 • 790-101-5151 • Plate t 1
5 • 790-101-5021 • Grip t 1
6 01010-50816 Bolt t 1
REMOVAL
k Lower the work equipment to touch the ground
completely and stop the engine. After that, slow-
ly loosen the cap of the hydraulic oil tank to re-
lease the inside pressure of the hydraulic oil
tank.
k Separate the (–) terminal of the battery.
a Put tags, etc. to each piping so that the mounting
position may not be mistaken.
4. Separate the hoses (5) and (6) and suction tube
1. Remove the hydraulic oil tank strainer and stop (7).
the oil using the tool S.
a In case the tool S is not used, remove the
drain plug to drain oil from the inside of the
hydraulic oil tank and from the inside of the
piping.
6 Hydraulic oil tank: Approx. 500 l
2. Open the engine hood and the rear cover of the

pump. After that, remove the upper cover of the
pump.
PC750, 800-7 30-77

(2)
5. By the hanging bolt, temporarily hang the main

pump (No. 2 pump) assembly (8) and remove
the mounting bolt to remove the pump.
4 Main pump assembly: 150 kg
INSTALLATION
• Installation shall be made in the reversed proce-
dure of the removal procedure.
• Filling the oil (Hydraulic oil tank)

a Fill the oil to the stipulated level from the oil
filler port, start the engine to circulate the oil
inside the piping and, after that, re-check the
oil level.
• Air Bleeding
a Carry out air bleeding of each section refer-
ring to the section "Testing and adjusting".
30-78 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL AND INSTALLATION OF MAIN PUMP INPUT SHAFT

OIL SEAL
1. Remove main pump assembly. • Carry out installation in the reverse order to
For details, see REMOVAL OF MAIN PUMP removal.
ASSEMBLY.
2. Remove cover (1). 2 Lip of oil seal: Grease (G2-LI)

a Be careful not to lose shims (2) and (3). 2 Coat the outside circumference of the
oil seal thinly with grease (G2-LI), then
press fit.
a Using tool , press fit oil seal (4).
3. Remove oil seal (4) from cover (1).
PC750, 800-7 30-79

(2)
DISASSEMBLY AND ASSEMBLY CONTROL AND PTO LUBRICATION PUMP
REMOVAL AND INSTALLATION OF CONTROL AND PTO LUBRI-

CATION PUMP ASSEMBLY
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
1 796-770-1301 Oil stopper t 1

2 209-60-71130 Rod assembly t 1
3 790-101-5001 Push tool kit t 1
S
4 • 790-101-5151 • Plate t 1
5 • 790-101-5021 • Grip t 1
6 01010-50816 Bolt t 1 INSTALLATION
REMOVAL
k Lower the work equipment to touch the ground • Filling the oil (Hydraulic oil tank)
completely and stop the engine. After that, slow- a Fill the oil to the stipulated level from the oil
ly loosen the cap of the hydraulic oil tank to re- filler port, start the engine to circulate the oil
lease the inside pressure of the hydraulic oil inside the piping and, after that, re-check the
tank. oil level.
k Separate the (–) terminal of the battery.
a Put tags, etc. to each piping so that the mounting • Air Bleeding
position may not be mistaken. a Carry out air bleeding of each section refer-
ring to the section "Testing and adjusting".
1. Remove the hydraulic oil tank strainer and stop
the oil using the tool S.
a In case the tool S is not used, remove the
drain plug to drain oil from the inside of the
hydraulic oil tank and from the inside of the
piping.
6 Hydraulic oil tank: Approx. 500 l
2. Open the rear cover of the pump.
3. Remove the suction hose and tube.
4. Separate the delivery port hoses (3) and (4).
5. Remove the control and PTO lubrication pump

assembly (6).
4 Pump assembly: 35 kg
30-80 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE

ASSEMBLY
DISASSEMBLY
1. Remove sleeve assembly (1) from sleeve (2).
2. Remove springs (3) and (4), pistons (5) and (6),

and sleeve (7).
3. Disassembly of sleeve assembly (1)

a Do not disassemble except when replacing
parts. Measure the protrusion of sleeves (9)
and (12) when disassembling.
a Loosen locknut (8), and remove sleeve (9)
and piston (10).
a Loosen locknut (11), and remove sleeve
(12), spring (13), and piston (14) from sleeve
(15).
ASSEMBLY
1. Assembly of sleeve assembly (1)
a Set sleeves (12) and (9) to the protrusion
measured when disassembling. After install-
ing to the control valve, adjust the relief pres-
sure.
ING.
1) Assemble piston (14) and spring (13) to
sleeve (15), then screw in sleeve (12) and
3 Locknut:
tighten locknut (11).
107.8 ± 14.7 Nm {11 ± 1.5 kgm}

2) Assemble piston (10) and sleeve (9) to
3 Locknut:
sleeve (12), and tighten locknut (8).
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 Sleeve: 186.2 ± 9.8 Nm {19 ± 1 kgm}

3. Install sleeve assembly (1).
PC750, 800-7 30-81

(2)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY

REMOVAL 3. Separate the PPC hose (3) of the pilot change
k Lower the work equipment to touch the ground over valve and the hose (4) between the control
completely and stop the engine. After that, slow- valve. After that, remove the valve assembly (5).
tank.
k Referring to the section Releasing the remaining
pressure from the hydraulic circuit" in the "Test-
ing and adjusting", release the remaining pres-
sure from the hydraulic circuit.
a Put the counter mark before separating the hose
and tube.
a Put the plug to the hose and tube.
1. Remove the control valve cover (1).
4. Remove the tubes (6) and sensor (7) between

t h e m a i n p u m p a n d r e m o v e t h e t u b e (8 )
between the 4-spool control valve and the 5-
spool control valve.
30-82 PC750, 800-7

(2)
a 4-spool control vale a 5-spool control vale

5. Separate the 14 pcs. of the PPC hoses (9). 9. Separate the LH swing motor hose (17).
6. Separate each tube of the travel (10), boom 10. Separate the RH swing motor hose (18).
(11), bucket (12) and arm (13).
11. Remove the tube clamp (19) and tube (20).
7. Separating the lower side back pressure com-
pensation valve hose. 12. Remove the piping brackets (21) and (22).
Separate the tube (14) between the 5-spool
control valve.
13. Separate each tube of the boom (23), swing

(24), arm (25), bucket (26) and travel (27).
8. Temporarily hang the 4-spool control valve and
remove the 3 pcs. of the mounting bolts (15) to 14. Separating the lower side back pressure com-
remove the control valve assembly (16). pensation valve hose.
4
Separate the sensor (7).
4-spool control valve assembly, RH: Separate the tube (28) between the 4-spool
250 kg control valve.
15. Separate the 16 pcs. of the PPC hoses (29).
PC750, 800-7 30-83

(2)
16. Temporarily hang the 5-spool control valve and INSTALLATION

remove the 3 pcs. of the mounting bolts (30) to • Installation shall be made in the reversed proce-
remove the control valve assembly (16). dure of the removal procedure.
4 5-spool control valve assembly, RH: a Install the tube (1) and adjust the mounting posi-
250 kg tion of the valve. After that, fasten the valve as-
3 Control valve assembly mounting bolt:

sembly mounting bolt (2).
279 ± 29 Nm {28.5 ± 3 kgm}
a 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.

oil level.
30-84 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY (WORK EQUIPMENT)
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY

(WORK EQUIPMENT)
DISASSEMBLY
a The operation described below is for the right 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 nut (13) and remove sleeve (14).
3. Remove spring (15) and check valve (16).
4. Remove seat (17), spring (18), and check valve

(19).
5. Pull out spool from valve body as follows.

1) Remove case (20), then remove springs
(21) and (22), and retainer (23).
2) Pull out spool (24) from valve body.
6. Pull out spool from valve body as follows.

1) Remove case (25), then remove springs
(26) and (27), and retainer (23).
2) Pull out spools (28), (29), and (30) from
valve body.
7. Remove orifice (31) and jet sensor relief valve

(32).
8. Remove suction-safety valves (33) and (34).
9. Remove suction valve (35).
10. Remove 2-stage safety valve (36).
11. Remove main relief valve (37).
PC750, 800-7 30-85

(2)
30-86 PC750, 800-7

(2)
ASSEMBLY 10. Assemble straight-travel valve as follows.

a The operation described below is for the right 4- 1) Fit O-ring and backup ring (38), then install
spool control valve (with straight-travel valve), sleeve (14), and tighten nut (13).
but the procedure is basically the same for the 2) Assemble check valve (12) and spring (11),
left 5-spool control valve also. then fit O-ring and backup ring (39) and
a Coat the sliding surface with engine oil when as- install plug (10).
sembling. 3) Assemble spring (9), spool (8), and piston
(7) to valve body, then fit O-ring and install
3 Main relief valve:

1. Fit O-ring and install main relief valve (37). sleeve (6).
4) Fit backup ring (5) and install plug (4).
320.95 ± 46.55 Nm {32.75 ± 4.75 kgm} 5) Install cover (3).
3 2-stage safety valve :

2. Fit O-ring and install 2-stage safety valve (36). 11. Fit O-ring, then fit straight-travel valve assembly
(2), and tighten mounting bolts (1).
225.4 ± 9.8 Nm {23 ± 1 kgm}
3 Suction valve:
3. Fit O-ring and install suction valve (35).
225.4 ± 9.8 Nm {23 ± 1 kgm}
4. Fit O-ring and install suction-safety valves (34)
3 Suction-safety valve:
and (33).
225.4 ± 9.8 Nm {23 ± 1 kgm}
5. Fit O-ring and install jet sensor relief valve (32)
3 Jet sensor relief valve :

and orifice (31).
3 Orifice:
186.2 ± 9.8 Nm {19 ± 1 kgm}
151.9 ± 24.5 Nm {15.5 ± 2.5 kgm}
6. Install spool to valve body as follows.

1) Assemble spools (30), (29), and (28) to
valve body.
2) Assemble retainer (23), and springs (26)
and (27), then fit O-ring and install case
(25).
7. Install spool to valve body as follows.

1) Assemble spool (24) to valve body.
2) Assemble retainer (23), and springs (22)
and (21), then fit O-ring and install case
(20).
8. Assemble check valve (19), spring (18), and

seat (17) to valve body.
9. Install check valve (16) and spring (15).
PC750, 800-7 30-87

(2)
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
REMOVAL AND INSTALLATION OF SOLENOID VALVE ASSEMBLY

REMOVAL 2. Straight traveling valve, 2-stage boom head
k Lower the work equipment to touch the ground safety valve, travel speed change-over valve,
completely and stop the engine. After that, slow- main 2-stage relief valve and CO canceling
ly loosen the cap of the hydraulic oil tank to re- valve
lease the inside pressure of the hydraulic oil 1) Make the access from the hole (1) of the
tank. lower surface of the revolving frame.
k Separate the (–) terminal of the battery. 2) Remove the clips (5) and (6).
a Put the counter mark before separating the PPC 3) Separate the wiring connectors (2) (V02, 03,
circuit hose. 05, 06 and 07).
a Put the plug to the separated tube and hose. 4) Remove the bolt (3) and remove the coil (4).
a V2 : Main 2-stage relief valve
1. Boom damping valve V3 : Straight traveling valve
1) Remove the tool box (1) positioned in front V5 : 2-stage boom head safety valve
of the hydraulic oil tank. V6 : Travel speed change-over valve
V7 : CO canceling valve
3. Swing holding brake valve

1) Make the access from the hole of the lower
surface of the revolving frame.
2) Remove the clip (5).
3) Separate the wiring connector (2) (V04).
4) Remove the bolt (3) and remove the coil (4).
a V4 : Swing holding brake valve
2) Separate the wiring connectors (2) (V9 and

V10).
3) Remove the nut (3) and remove the coil (4).
a V9 and V10:
Boom damping solenoid valve
30-88 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
4. Swing priority change-over valve INSTALLATION

1) Make the access from the hole of the lower • Installation shall be made in the reversed proce-
surface of the revolving frame. dure of the removal procedure.
2) Remove the clip (5). a Pay attention so that dust, etc. shall not adhere
3) Separate the wiring connector (2) (V04). to the coil insertion section.
4) Remove the bolt (3) and remove the coil (4).
a V1 : Swing priority change-over valve
PC750, 800-7 30-89

(2)
DISASSEMBLY AND ASSEMBLY BOOM DAMPING VALVE
REMOVAL AND INSTALLATION OF BOOM DAMPING VALVE

ASSEMBLY
k Lower the work equipment to touch the ground • Installation shall be made in the reversed proce-
completely and stop the engine. After that, slow- dure of the removal procedure.
lease the inside pressure of the hydraulic oil • Air Bleeding
tank. Carry out air bleeding of the PPC piping circuit
k Separate the (–) terminal of the battery. referring to the section "Air bleeding of each
a Release the remaining pressure from the PPC section" in the "Testing and adjusting".
circuit.
a Put the 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.
a Separate the hose between the damping
valve and the PPC valve, RH and separate
the hose between the damping valve and the
relay joint.
4. Remove the mounting bolt to remove the damp-

ing valve assembly (5).
30-90 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY
REMOVAL a Front side of the machine body

k Lower the work equipment to touch the ground 1. Separate the hoses (10) and (11) from the swing
completely and stop the engine. motor positioned in the central section of the
machine body.
k 1) Referring to the section "Releasing the re-
maining pressure from the hydraulic circuit 2. Separate the swing holding brake hose (12) and
on PPC valve installed machines" in the the drain hose (13).
"Testing and adjusting", release the remain-
ing pressure from the hydraulic circuit.
2) Slowly loosen the cap of the hydraulic oil
tank to release the inside pressure of the
hydraulic oil tank.
a Center side of the machine body
1. Separate the hoses (1) and (2) from the control
valve and separate the hoses (3) and (4) to the
swing motor positioned in the front section of the
machine body.
2. Separate the swing holding brake hose (5) and

the drain hose (6).
3. Remove the U-bolt (7) of the oil gauge tube, 3. Separate the swivel joint section hose (14).
remove the bolt (8) and remove the bracket (9).
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 x 2
PC750, 800-7 30-91

(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR
INSTALLATION
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.
a Fill the quantity of the oil which leaked when
the motor assembly was removed.
30-92 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT

REMOVAL
k Lower the work equipment to touch the ground
completely and stop the engine. After that, slow-
tank.
1. Separate the lower section hoses (1), (2), (3)

and (4) of the swivel joint.
INSTALLATION
a Regarding the port positioned in the lower

section of the swivel joint, install the swivel
2. Separate the upper section hoses (5), (6), (7) joint so that the "A port" may be directed to
and (8) of the swivel joint. the front-RH side.
3. Pull out the pin (9) and shift the link (10) to the • Filling the oil
direction of the frame side. a Fill the oil to the stipulated level from the oil
a Separate the hose (12) between the swing filler port and circulate the oil inside the pip-
motor. ing. After that, re-check the oil level.
a Fill the quantity of the oil which leaked when
4. Temporarily hang the swivel joint assembly. the swivel joint assembly was removed.
a Use the hole of the split flange bolt.
5. Removing the lower side mounting bolt, hang

the swivel joint assembly (11) to remove it.
4 Center swivel joint assembly: 70 kg
PC750, 800-7 30-93

(2)
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT

ASSEMBLY
SPECIAL TOOLS
New/Remodel
1
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
2
3
790-101-2501 Push-puller t 1
• 790-101-2510 • Block t 1
• 790-101-2520 • Screw t 1 4
• 791-112-1180 • Nut t 1
T • 790-101-2540 • Washer t 1
7
• 790-101-2630 • Leg t 2
• 790-101-2570 • Plate t 2
6
• 790-101-2560 • Nut t 2
• 790-101-2660 • Adapter t 2
5
DISASSEMBLY
1. Remove cover (1).
CEP00381
2. Remove snap ring (2).
3. Using push-puller T, pull out swivel rotor (4) and

ring (3) from swivel shaft (5).
4. Remove O-ring (6) and slipper seal (7) from

swivel rotor.
30-94 PC750, 800-7

(2)
ASSEMBLY
1. Assemble slipper seal (7) and O-ring (6) to
swivel rotor.
2. Set swivel shaft (5) on block, then using push-

puller T, tap swivel rotor (4) with a plastic ham-
2 Contact surface of rotor, shaft:

mer to install.
Grease (G2-LI)
a When installing the rotor, be extremely care-
ful not to damage the slipper seal and O-ring.
3. Install ring (3) and secure with snap ring (2).
3 Mounting bolt:
4. Fit O-ring and install cover (1).
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
PC750, 800-7 30-95

(2)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY
SPECIAL TOOLS 3. Remove 2 mounting bolts from travel motor and

set tool K in position.
New/Remodel
Necessity
4. Remove remaining mounting bolts, then pull out
Symbol
Sketch
Q’ty
Part No. Part Name travel motor assembly (6) and sling.
5. Lift off travel motor assembly (6).
4
K 796-660-1560 Guide-bolt t 2 N
Travel motor assembly: 140 kg
REMOVAL
k Swing the work equipment 90°, then lower it
completely to the ground.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
1. Lift off cover (1).
4 Cover: 120 kg
INSTALLATION
removal.
a After connecting the hoses, add engine oil

through plug (7) until it reaches the bottom of
the port.
3 Mounting bolt:
2. Disconnect hoses (2), (3), (4), and (5).
384.7 ± 41.65 Nm {39.25 ± 4.25 kgm}
a Fit plugs into the hoses.
a There is no air bleed plug, so add oil through

the brake valve side plug when installing.
a Run the engine to circulate the oil through
the system. Then add engine oil to the hy-
draulic tank to the specified level.
30-96 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC

VALVE ASSEMBLY
DISASSEMBLY
1. Remove nut (1), then remove disc (2) and boot
(3).
2. Remove bolt, then remove plate (5).

a Do not remove joint (4) unless it is to be re-
placed.
3. Remove seal (6) and collar (7).
4. Pull out piston (8), and remove retainer (9),

springs (10) and (11), and shim (12).
a Spring (10) consists of two springs each of
two types with different installed loads, so
check the mounting position (hydraulic port)
and mark with tags to prevent mistakes
when installing.
5. Pull out valve (13) from body (14).
PC750, 800-7 30-97

(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
2 Joint sliding surface: Grease (G2-LI)

ASSEMBLY 6. Install joint (4).
2 Female thread in body:

1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) to valve Thread tightener (LT-2)
(13). a Coat two places on the female thread with
a When assembling spring (11), set the end one drop of Loctite each as shown in the di-
3 Joint: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}

with the small coil diameter (inside diameter) agram below.
at shim (12) end.
a Keep strictly to the tightening torque for the
3. Assemble spring (10), retainer (9), and piston joint.
(8).
a The number of loops in the coil for spring
(10) is different for each of the hydraulic
ports below, so be careful when installing.
Positon of port Free length of spring (mm)

P1, P2 38.71
P3, P4 42.48
a The position of each port is marked at the
2 Piston: Grease (G2-LI)

bottom of the valve body. CEP00425
a When assembling piston (8), coat the out- 7. Assemble boot (3) and disc (2), and tighten with
3 Nut: 112.7 ± 14.7 Nm {11.5 ± 1.5 kgm}

side circumference of the piston and the in- nut (1).
side circumference of the hole in the body
with grease. a After assembling the disc, adjust the height
of the disc.
4. Fit O-ring to collar (7) and assemble to body For details, see TESTING AND ADJUST-
(14), then install seal (6). ING, Adjusting PPC valve.
3 Mounting bolt:
5. Install plate (5).
13.23 ± 1.47 Nm {1.35 ± 0.15 kgm}
30-98 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE

ASSEMBLY
DISASSEMBLY
1. Remove screw (1), then remove lever (2).
2. Remove mounting bolt (3), then remove case

and shaft assembly (4).
3. Remove 4 mounting bolts (5), then remove plate

and damper assembly (6).
a Check the thickness and mounting position
of washer (7).
4. Remove mounting bolt (8), then remove damper

assembly (9) from plate (10).
5. Remove seal (11) and collar (12).
6. Pull out piston (13), and remove retainer (14),

springs (15) and (16), and shim (17).
a Check the number and thickness of shims
(17) for each mounting position, and keep in
a safe place.
7. Pull out valve (18) from body (19).
8. Disassembly of case and shaft assembly

1) Knock pin (20) in shaft and remove shaft
(21).
2) Remove lever (22).
3) Pull out pin (20) from shaft (21).
PC750, 800-7 30-99

(2)
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
ASSEMBLY
1. Assemble valve (18) to body (19).
2. Assemble shim (17) and spring (16) to valve

(18).
a Assemble the same number and thickness
of shim (17) in the same position as was re-
moved during disassembly.
Standard shim thickness : 0.3 mm
a Spring (16) is not symmetrical at the top and
bottom, so assemble with the small coil di-
ameter (inside diameter) at the shim end.
3. Assemble spring (15), retainer (14), and piston
2 Outside circumference of piston, body

(13).
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).
a Temporarily assemble standard washer (1.6
mm) for washer (7).
After completing the assembly, measure the
difference in the angle when the left and
right levers are operated fully. If the angle is
greater than 0.7°, change the thickness of
washer (7) to make the difference less than
0.7°.
• Washer thickness 1.0, 1.3, 1.6 mm
a If the washer is made 0.3 mm thinner,
the angle at the full stroke is increased
3 Mounting bolt:
by 0.39°.
30.87 ± 3.43 Nm {3.15 ± 0.35 kgm}
7. Install case and shaft assembly (4), and tighten
2 Rocking portion of shaft, connection of

mounting bolt (3).
3 Mounting bolt:
lever and piston: Grease (G2-LI)
27.95 ± 3.43 Nm {2.85 ± 0.35 kgm}
2 Rocking portion of lever pin and plate:

8. Install lever (2), and tighten screw (1).
3 Screw: 8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}

Grease (G2-LI)
30-100 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL AND INSTALLATION OF BUCKET CYLINDER

ASSEMBLY
BACK HOE
REMOVAL
k Retract the arm and bucket cylinder piston rods,
lower the work equipment completely to the
ground, then set the safety lock lever to the 7 6
LOCK position. 5
1. Set block between bucket cylinder and arm,

and block between link and arm.
2. Remove 3 pin lock bolts (1) and cover (2), then

using forcing screws, pull out.
shims, and keep in a safe place. CEP00077
INSTALLATION
removal.
2 Inside surface of bushing when assem-

bling pin: Anti-friction compound
2 Grease after assembling pin:

(LM-P)
Grease (LM-G)
k When aligning the position of the pin hole,
3. Start engine, and retract piston rod, then tie pis- never insert your fingers in the hole.
ton rod with wire to prevent it from coming out. a Adjust with shims (4) so that the clearance a
k Stop the engine and release the remaining between link (7) and cover (2) is less than 1
pressure in the circuit. For details, see mm.
TESTING AND ADJUSTING, Releasing • Shim thickness: 0.8 mm (STD)
pressure in hydraulic circuit. 1.0 mm (SE)
4. Disconnect 2 hoses (3).

a Fit plugs in the hoses to prevent dust or dirt
from entering.
5. Sling bucket cylinder assembly (5), then remove

plate (6) and pull out pin (7).
a There are shims installed, so check the
number, thickness, and position, and keep in
a safe place.
6. Remove bucket cylinder assembly (5).
4 Bucket cylinder assembly:

550 kg (PC750)
980 kg (PC750SE, PC800SE)
600 kg (PC800)
PC750, 800-7 30-101

(2)


(LM-P)
Grease (LM-G)
k When aligning the position of the pin hole, never
insert your fingers in the hole.
a Adjust with shims (9) so that the clearance b
between bracket (8) and the end face of of
bottom of cylinder (5) is less than 1 mm.
• Shim thickness: 0.8 mm (STD)
1.0 mm (SE)
• Bleeding air
a Bleed the air.
ING, Bleeding air.
• Refilling with oil (hydraulic tank)

a Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
30-102 PC750, 800-7

(2)
REMOVAL AND INSTALLATION OF BUCKET CYLINDER

ASSEMBLY
LOADING SHOVEL
REMOVAL 3. Disconnect grease tube (4).

k Extend the arm cylinder fully, set the bottom of
the bucket horizontal, lower the work equipment 4. Disconnect hose (5).
completely to the ground and stop the engine.
Operate the control levers several times to re-
lease the remaining pressure in the hydraulic
piping.
a Fit plugs in the hoses after disconnecting them,
to prevent dirt or dust from entering.
1. Sling bucket cylinder assembly, and remove 3

mounting bolts, then using forcing screws
(Thread dia. = 16 mm, Pitch = 2.0 mm), remove
pin (1).
k When the pin is removed, links (2) and (3) 5. Sling piston rod end and bottom end, and
will drop, so sling the links before removing remove plate, then using forcing screws (Thread
4 Pin: 37 kg
the pin. dia. = 16 mm, Pitch = 2.0 mm), pull out pin (6).
a Pull out the pin to a position where the cylin-

der bottom can be disconnected.
4 Pin: 35 kg
2. Start engine and retract piston rod fully.

k Tie the rod with wire to prevent it from com-
ing out.
k After stopping the engine, release the pres-
sure inside the piping. 6. Raise bucket cylinder assembly (7) carefully and
For details, see TESTING AND ADJUST- remove.
ING, Releasing pressure in PPC circuit.
4 Bucket cylinder assembly: 555 kg
PC750, 800-7 30-103

(2)
INSTALLATION
removal.
k When aligning the mounting position of the

pin, do not insert your fingers in the pin hole.

a Adjust with shims so that the clearance
at the cylinder bottom end is less than 1
mm.
a Bleed the air from the work equipment circuit.

Bleeding air from hydraulic cylinder.
• Refilling with oil

a Add oil to the specified level, and run the en-
gine to circulate the oil through the system.
Then check the oil level again.
30-104 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY

BACK HOE
SPECIAL TOOLS a If the pin does not come out, use tool V2 and
remove the pin from the head end.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
791-650-1610 Bracket t 1
790-445-4130 Screw t 1
791-112-1180 Nut t 1
V 2
01643-32780 Washer t 1
Puller (294 kN
790-101-2102 t 1
{30 ton})
4. Start engine, and retract piston rod, then tie pis-
790-101-1102 Pump t 1 ton rod with wire to prevent it from coming out.
k Stop the engine and release the remaining
pressure in the circuit. For details, see
REMOVAL TESTING AND ADJUSTING, Releasing
k Extend the arm cylinder piston rod to a point ap- pressure in hydraulic circuit.
prox. 200 mm before the end of the IN stroke,
lower the work equipment completely to the 5. Disconnect hose (4) and grease hose (5).
ground, then set the safety lock lever to the a Fit plugs in the hoses to prevent dust or dirt
LOCK position. from entering.
1. Set block between arm cylinder and boom. 6. Sling arm cylinder assembly (6), then remove
plate (7) and pull out bottom pin (8).
2. Disconnect grease hose (1). a If the pin does not come out, use tool V2 and
remove the pin from the bottom end.
3. Remove plate (2), and pull out head pin (3). a There are shims installed, so check the
a safe place.
4
7. Remove arm cylinder assembly (6).
4 Arm cylinder assembly:

1 915 kg (PC750STD)
540 kg x 2 (PC750SE, PC800, PC800SE)
2
3
8 7 5
CEP00522
CEP00523
PC750, 800-7 30-105

(2)
• Bleeding air
a Bleed the air.
ING, Bleeding air.

INSTALLATION
removal.


(LM-P)
Grease (LM-G)
never insert your fingers in the hole.


(LM-P)
Grease (LM-G)
a Adjust with shims (10) so that the clearance
a between bracket (9) and the bottom end
face of cylinder (6) is less than 1 mm.
• Shim thickness: 0.8 mm
30-106 PC750, 800-7

(2)
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY

LOADING SHOVEL
REMOVAL 3. Start engine and retract piston rod fully.

k Retract boom cylinder fully, and extend arm cyl- k Tie the rod with wire to prevent it from com-
inder, then set the bottom of the bucket horizon- ing out.
tal, lower the work equipment completely to the k After stopping the engine, release the pres-
ground and stop the engine. Operate the control sure inside the piping.
levers several times to release the remaining For details, see TESTING AND ADJUST-
pressure in the hydraulic piping. ING, Releasing pressure in PPC circuit.
pressure inside the hydraulic tank. 4. Disconnect hose (3).
a Fit blind plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering. 5. Sling piston rod end and bottom end, and
remove plate, then using forcing screws (Thread
1. Disconnect grease tube (1) at piston rod end. dia. = 16 mm, Pitch = 2.0 mm), pull out pin (4).
a Pull out the pin to a position where the cylin-

der bottom can be disconnected.
4 Pin: 56 kg
2. Sling arm cylinder assembly, and remove plate,

then using forcing screws (Thread dia. = 16 mm,
Pitch = 2.0 mm), pull out pin (2).
a Pull out the pin to a position where the piston
rod can be disconnected.
4
6. Lift off arm cylinder assembly (5) carefully.
4
Pin: 56 kg
Arm cylinder assembly: 845 kg
PC750, 800-7 30-107

(2)
INSTALLATION
removal.
k When aligning the mounting position of the pin,

do not insert your fingers in the pin hole.
k When aligning the mounting position of the pin,
do not insert your fingers in the pin hole.
a Adjust with shims so that the clearance at the
cylinder bottom end is less than 1 mm.


30-108 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY

BACK HOE
SPECIAL TOOLS 3. Sling boom cylinder assembly.
New/Remodel
4. Using tool V3, pull out head pin (3), then discon-
Necessity
nect piston rod from boom.
Symbol
Sketch
Q’ty
Part No. Part Name
790-445-4100 Remover t 1
Puller (294 kN
1 790-101-4200 t 1
{30 ton})
790-101-1102 Pump t 1
790-445-4120 Sleeve t 1
791-520-4140 Screw t 1
V
796-775-1110 Adapter t 1
t 1 5. Start engine, and retract piston rod, then tie pis-
3 791-112-1180 Nut ton rod with wire to prevent it from coming out.
01643-32780 Washer t 1 k Stop the engine and release the remaining
Puller (294 kN pressure in the circuit. For details, see
790-101-2102 t 1 TESTING AND ADJUSTING, Releasing
{30 ton})
pressure in hydraulic circuit.
790-101-1102 Sleeve t 1
6. Lower boom cylinder assembly on stand, then
disconnect hose (4).
REMOVAL
k Retract the arm and bucket cylinder piston rods 7. Disconnect grease hose (5).
fully, lower the work equipment completely to the
ground, then put the safety lock lever in the 8. Sling boom cylinder assembly and remove plate
LOCK position. (6).
a Fit plugs in the hoses to prevent dust or dirt from
entering.
1. Disconnect grease tube (1).
2. Remove plate (2).
PC750, 800-7 30-109

(2)
9. Using tool V1, pull out bottom pin (7). INSTALLATION

10. Remove boom cylinder assembly. removal.
4 Boom cylinder assembly: 840 kg x 2


(LM-P)
Grease (LM-G)


(LM-P)
Grease (LM-G)
a Adjust with shims (10) so that the clearance
a between bracket (9) and the bottom end
face of boom cylinder (8) is less than 1 mm.
• Shim thickness: 1.0, 1.5 mm
• Bleeding air
a Bleed the air.
ING, Bleeding air.

30-110 PC750, 800-7

(2)
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY

LOADING SHOVEL
REMOVAL 6. Sling boom cylinder assembly, and remove

k Extend the arm and bucket fully, lower the work plate, then using forcing screws (Thread dia. =
equipment completely to the ground and stop 16 mm, Pitch = 2.0 mm), pull out foot pin (5).
the engine. Operate the control levers several
times to release the remaining pressure in the
hydraulic piping.
1. Disconnect grease hose (1).
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 7. Remove boom cylinder assembly (6).
from boom.
4 Boom cylinder assembly: 720 kg
4. Start engine and retract piston rod fully.

k Tie the rod with wire to prevent it from com-
ing out.
k After stopping the engine, release the pres-
sure inside the piping.
ING, Releasing pressure in PPC circuit.
5. Lower boom cylinder assembly onto stand, then

disconnect hose (4).
PC750, 800-7 30-111

(2)
INSTALLATION
removal.


a Adjust with shims so that the clearance
at the cylinder bottom end is less than 1
mm.
a Bleed the air from the work equipment cir-

cuit.
ING, Bleeding air from hydraulic cylinder.

30-112 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY BOTTOM DUMP CYLINDER
REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER

ASSEMBLY
LOADING SHOVEL
REMOVAL 5. Remove 3 mounting bolts, then using forcing

k Set the bottom of the bucket horizontal, and re- screws (Thread dia. = 16 mm, Pitch = 2.0 mm),
tract the rod to a position where the rod connect- pull out pin (4).
4
ing pin of the bottom dump cylinder can be
removed. Then fit a block under the bucket, low- Pin: 35 kg
er the work equipment completely to the ground
and stop the engine. 6. Lift off bottom dump cylinder assembly (5).
4
to prevent dirt or dust from entering. Bottom dump cylinder assembly:
140 kg
1. Remove cover (1).
2. Sling bottom dump cylinder assembly, and

remove lock plate, then using forcing screws
(Thread dia. = 16 mm, Pitch = 2.0 mm), pull out
pin (2).
INSTALLATION
removal.
3. Start engine and retract piston rod fully. k When aligning the mounting position of the
k After stopping the engine, release the pres- pin, do not insert your fingers in the pin hole.
sure inside the piping.
ING, Releasing pressure in PPC circuit. k When aligning the mounting position of the
4. Remove hose (3).

PC750, 800-7 30-113

(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER

ASSEMBLY
SPECIAL TOOLS a Place a container under the cylinder to
catch the oil.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
Cylinder repair
1 790-502-1003 t 2
stand
2 790-720-1000 Expander t 1 N Q
796-720-1690 Ring t 1
796-720-1720 Ring t 1
07281-02169 Clamp t 1
3 4) Disassemble piston rod assembly as fol-
796-720-1690 Ring t 1 lows.
07281-01919 Clamp t 1 i) Set piston rod assembly (2) to tool U1.
07281-02429 Clamp t 1
790-201-1702 Push took kit t 1
• 790-201-1881 • Push tool t 1
• 790-201-1871 • Push tool t 1
• 791-863-1110 • Push tool t 1
U 4
• 790-101-5421 • Grip t 1
• 01010-51240 • Blot t 1
• 790-101-5021 • Grip t 1
• 01010-50816 • Bolt t 1 ii) Remove piston assembly stopper screw
(3).
790-201-1500 Push tool kit t 1 • Applicable to:
Boom and arm cylinder for standard
• 790-201-1690 • Plate t 1
and SE specifications.
• 790-201-1680 • Plate t 1 Bucket cylinder for standard specifi-
5 cation.
• 792-715-1400 • Push tool t 1 Screw size: M12 x pitch 1.75
• 790-101-5421 • Grip t 1
• 01010-51240 • Bolt t 1
• 790-101-5021 • Grip t 1
6
• 01010-51240 • Blot t 1
DISASSEMBLY
1. Piston rod assembly
1) Remove piping from cylinder assembly.
2) Remove mounting bolts, and disconnect
head assembly (1).
3) Pull out piston rod assembly (2).
30-114 PC750, 800-7

(2)
a If screw (3) has been caulked iv) Remove 6 screws (21), then remove
strongly and cannot be removed, spacer (22), and remove piston ass’y
screw it in fully, then fit a tap to the (4) and O-ring, back-up ring (23).
thread and pull it out. • Applicable to bucket cylinder for SE
specification.
iii) Using tool U6, remove piston assembly

(4). v) Remove plunger (5).
• When not using tool U6, use the drill vi) Remove collar (6).
holes ( 10: 4 places) and loosen vii) Remove head assembly (7).
the piston assembly.
• Applicable to:
Boom and arm cylinder for standard
and SE specifications.
Bucket cylinder for standard specifi-
cation.
viii) Remove cap (8), and pull out 11 balls

(9), then remove cushion plunger (10).
• Applicable to arm cylinder.
PC750, 800-7 30-115

(2)
2. Disassembly of piston assembly ASSEMBLY

1) Remove ring (11). a Be careful not to damage the packings, dust
2) Remove wear ring (12). seals, and O-rings.
a Two pieces are installed to each of the a Do not try to force the backup ring into position.
bucket cylinder and boom cylinder, and Warm it in warm water (50 – 60°C) before fitting
four pieces to the arm cylinder. it.
3) Remove piston ring (13).
4) Remove O-ring and backup ring (14). 1. Assembly of cylinder head assembly
1) Using tool U4, press fit bushing (20).
2) Assemble buffer ring (19).
3) Assemble rod packing (18).
4) Using tool U5, install dust seal (17), and
secure with snap ring (16).
5) Install backup ring and O-ring (15).
3. Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (15).
2) Remove snap ring (16), then remove dust
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
30-116 PC750, 800-7

(2)
2. Assembly of piston assembly 2) Assemble head assembly (7).

1) Using tool U2, expand piston ring (13). 3) Fit O-ring and backup ring to collar (6), then
a Set the piston ring on tool U2, and turn assemble.
the handle 8 – 10 times to expand the 4) Assemble plunger (5).
ring. a After tightening the piston, check that the
2) Set tool U3 in position, and compress piston plunger has a little play.
ring (13).
5) Set cushion plunger (10) to piston rod, then

3) Install backup ring and O-ring (14). assemble 11 balls (9), and secure with cap
4) Assemble wear ring (12). (8).
5) Assemble ring (11). • Applicable to arm cylinder
a Be careful not to open the end gap of the a After installing, check that the cushion
2 Ring groove : Grease (G2-LI)

ring too wide. plunger end has a little play.
3. Piston rod assembly

1) Set piston rod assembly (2) to tool U1.
PC750, 800-7 30-117

(2)
6) Assemble piston assembly (4) as follows. a. Screw in until piston assembly (4)
i) When using rod and piston assembly contacts end face of rod, then use
3 Piston assembly (4):

(2) again tool U6 to tighten.
a Wash thoroughly and remove all
metal particles and dirt. 294 ± 29.4 Nm {30 ± 3.0 kgm}
a. Screw in piston assembly (4), then a After tightening the piston,
use tool U6 to tighten piston assem- check that there is play in plung-
bly so that position of screw thread er (5).
hole matches.
a Remove all burrs and flashes
with a file.
b. Machine one hole used to install

screw (3).
a Apply the drill to the V-groove
3 Screw (3):
b. Tighten screw (3). between piston (4) and thread-
ed part of rod (2), and make a
58.9 – 73.6 Nm {6 – 7.5 kgm} hole horizontally.
c. Caulk thread at 2 places with a For the cylinder with bottom
punch. cushion (arm cylinder), avoid
the cushion plug position when
machining.
• Screw machining dimension
(mm)
Drill Bottom Tap

Cylinder Tap used
diameter hole depth depth
Bucket
10.3 36 12 x 1.75 29
Boom
Arm 10.3 43 12 x 1.75 36
ii) When using a new part for either or both

of rod or piston assembly (2)
a For the rod with bottom cushion,
mark the cushion plug position on
the end face of the rod.
• Applicable to arm cylinder
30-118 PC750, 800-7

(2)
2 Seal portion: Grease (G2-LI)

c. After machining, wash thoroughly to 8) Assemble piston rod assembly (2).
remove all metal particles and dust.
2 Threaded part: Thread

d. Tighten screw (3). a Set the end gap of the ring at the hori-
zontal (side) position, align the axial
tightener (Locktite No. center of shaft and cylinder tube, then in-
3 Screw:
262 or equivalent) sert.
a After inserting, check that the ring is not
58.9 – 73.6 Nm {6 – 7.5 kgm} broken and has not come out, then push
e. Caulk thread at 4 places with in fully.
punch.
9) Tighten head assembly (1) with mounting
3 Mounting bolt :
7) Install O-ring, back-up ring (23), piston ass’y bolts.
(4) and spacer (22), then retighten them
2 Threaded part: Thread tightener

with screw (21).
Cylinder Tightening torque
(Locketite No. 262 or equivalent) STD Bucket, 892 ± 137 Nm
• Applicable to bucket cylinder of SE spec- SE Arm {91.0 ± 14 kgm}
ification
STD Arm, 1,270 ± 200 Nm
Boom {130 ± 20 kgm}
1,670 ± 250 Nm
SE Bucket
{170 ± 25 kgm}
10) Install piping.
PC750, 800-7 30-119

(2)
DISASSEMBLY AND ASSEMBLY BUCKET
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY

BACK HOE
REMOVAL 7. Start engine and raise work equipment, discon-

k Set the back of the bucket facing down, lower nect arm from bucket, then remove bucket
the work equipment completely to the ground, assembly.
4
then set the safety lock lever to the LOCK posi-
tion. Bucket assembly:
2,960 kg (PC750STD)
1. Remove 3 pin lock bolts (1), then remove stop- 3,560 kg (PC800STD)
per (2). 3,435 kg (PC750SE)
3,870 kg (PC800SE)
INSTALLATION
removal.


(LM-P)
Grease (LM-G)
2. Using forcing screws, remove connecting pin of never insert your fingers in the hole.
link and bucket.
3. Start engine, and retract piston rod, then tie link 2 Inside surface of bushing when assem-
to arm with wire to prevent piston rod from com- bling pin: Anti-friction compound

ing out. (LM-P)
k Stop the engine and release the remaining Grease (LM-G)

pressure in the circuit. For details, see k When aligning the position of the pin hole,
TESTING AND ADJUSTING, Releasing never insert your fingers in the hole.
pressure in hydraulic circuit. a Insert the O-ring at the end face of the bucket
boss securely.
4. Remove 3 pin lock bolts (3), then remove stop- a Adjusting of bucket clearance
per (4). 1) Measure clearance a between arm (8) and
bushing (9).
5. Remove cover (5), then remove shims (6). a It is easier to measure if the bucket is
a Check the number and thickness of the moved to one side so that all the play is
shims, and keep in a safe place. in one place.
2) Select shims so that clearance a is 0.5 to
6. Using forcing screws, remove arm connecting 1.0 mm.
pin (7). • Shim thickness b: 0.5, 1.0 mm
3) Install selected shims and install cover (5).
30-120 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY BUCKET
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY

LOADING SHOVEL
REMOVAL 3. Sling bucket assembly, and remove 3 mounting

k Set the bottom of the bucket horizontal, lower bolts, then using forcing screws (Thread dia. =
the work equipment completely to the ground 16 mm, Pitch = 2.0 mm), pull out pin (4).
and stop the engine. Operate the control levers a Remove the pin on the other side in the
several times to release the remaining pressure same way.
4
in the hydraulic piping.
k Loosen the oil filler cap slowly to release the Pin: 52 kg
1. Disconnect bottom dump cylinder hose (1).
2. Sling bucket cylinder assembly, and remove 3

mounting bolts, then using forcing screws
(Thread dia. = 16 mm, Pitch = 2.0 mm), pull out
pin (2).
a Remove the pin on the other side in the
same way.
k When the pin is removed, link (3) will drop,
so sling the links before removing the pin. 4. Lift off bucket assembly (5).
4 Pin: 37 kg 4 Bucket assembly: 5,700 kg
4 Link: 440 kg
INSTALLATION
removal.


After completion of the air bleeding operation,
add engine oil to the hydraulic tank to the speci-
fied level.
PC750, 800-7 30-121

(2)
DISASSEMBLY AND ASSEMBLY ARM
REMOVAL AND INSTALLATION OF ARM ASSEMBLY

BACK HOE
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
5
Q’ty
Part No. Part Name 6
2
3
4
791-650-1610 Bracket t 1
790-445-4130 Screw t 1 1
791-112-1180 Nut t 1
2
01643-32780 Washer t 1 CEP00525
Puller (294 kN
790-101-2102 t 1 a If the pin does not come out, use tool V2 and
{30 ton})
remove the pin from the head end.
790-101-1102 Pump t 1
V 790-445-4120 Sleeve t 1
791-520-4140 Screw t 1
796-775-1110 Adapter t 1
3 791-112-1180 Nut t 1
01643-32780 Washer t 1
Puller (294 kN
790-101-2102 t 1
{30 ton})
790-101-1102 Sleeve t 1
6. Start engine, and retract piston rod, then tie pis-

ton rod with wire to prevent it from coming out.
k Stop the engine and release the remaining
REMOVAL
1. Remove bucket assembly. pressure in the circuit. For details, see
F o r d e t a i l , s e e R E M O VA L O F B U C K E T TESTING AND ADJUSTING, Releasing
ASSEMBLY. pressure in hydraulic circuit.
2. Secure link to arm with wire.
k Extend the arm cylinder piston rod to a point
7. Disconnect 2 bucket cylinder hoses (4).
approx. 200 mm before the end of the IN
stroke, then lower the arm on to block
and stand , and set the safety lock lever
to the LOCK position. Then, stop the en-
gine.
3. Set block between arm cylinder and boom.
4. Disconnect grease hose (1).
5. Remove plate (2), and pull out head pin (3) of

arm cylinder.
30-122 PC750, 800-7

(2)
8. Remove plate (5), then using tool V3, pull out INSTALLATION
boom top pin (6). • Carry out installation in the reverse order to
a There are shims installed, so check the removal.
a safe place.

(LM-P)
Grease (LM-G)


(LM-P)
9. Start engine, then raise boom and remove arm Grease (LM-G)
assembly (7). k When aligning the position of the pin hole,
4
Arm assembly: a Adjust with shims so that the clearance a be-
3,960 kg (PC750STD) tween boom (8) and the bottom end face of
4,530 kg (PC800STD) arm (7) is less than 1 mm.
4,930 kg (PC750SE, PC800SE) • Shim thickness : 1.0 mm
CEP00526
• Bleeding air
a Bleed the air.
ING, Bleeding air.

PC750, 800-7 30-123

(2)
REMOVAL AND INSTALLATION OF ARM ASSEMBLY

LOADING SHOVEL
REMOVAL 6. Remove 3 mounting bolts (5), then remove

1. Remove bucket assembly. potentiometer (6) together with bracket (7).
F o r d e t a i l s , s e e R E M O VA L O F B U C K E T
ASSEMBLY.
2. Start engine, and set work equipment so that

bucket cylinder is perpendicular.
3. Remove 3 mounting bolts, then using forcing

screws (Thread dia. = 16 mm, Pitch = 2.0 mm),
pull out pin (1).
a Remove the pin on the other side in the
same way, then secure the link to the arm
with wire so that it cannot move.
7. Remove arm cylinder from arm.

For details, see REMOVAL OF ARM CYLINDER
ASSEMBLY.
a Secure the arm cylinder assembly to the
boom with lever block .
4. Disconnect left and right bottom dump cylinder

hoses (2).
5. Remove cover (3), and disconnect wiring (4) of

potentiometer.
8. Sling arm assembly, and remove 3 mounting

bolts, then using forcing screws (Thread dia. =
16 mm, Pitch = 2.0 mm), pull out pin (8).
a Pull out the pin on the other side in the same
way to a position where the arm can be dis-
connected from the boom.
4 Pin: 45 kg
30-124 PC750, 800-7

(2)
9. Lift off arm assembly (9). INSTALLATION
4
Arm assembly: 3,070 kg removal.


fied level.
PC750, 800-7 30-125

(2)
DISASSEMBLY AND ASSEMBLY BOOM
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY

BACK HOE
SPECIAL TOOLS 5. Sling boom assembly (10).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
790-445-4100 Remover t 1
Puller (294 kN
V 1 790-101-4200 t 1
{30 ton})
10
790-101-1102 Pump t 1
CEP00299
REMOVAL 6. Using tool V1, remove 2 boom foot pins (7), then
1. Remove bucket and arm assembly. remove boom assembly.
For details, see REMOVAL OF BUCKET, ARM a There are shims installed, so check the
ASSEMBLY. number, thickness, and position, and keep in
k Lower the boom assembly completely to the
a safe place.
4
ground, then set the safety lock lever to
LOCK position. Boom assembly:
8,360 kg (PC750 STD)
2. Disconnect boom cylinder assembly from boom. 8,790 kg (PC800 STD)
For details, see REMOVAL OF BOOM CYLIN- 7,970 kg (PC750SE, PC800SE)
DER ASSEMBLY.
3. Disconnect front lamp wiring.
4. Disconnect bucket cylinder hoses (1) and arm

cylinder hoses (2).
30-126 PC750, 800-7

(2)
INSTALLATION
removal.


(LM-P)
Grease (LM-G)
a Adjust with shims so that the clearance a be-
tween bracket (4) and the end face of the
foot of boom (3) is less than 1 mm.
• Shim thickness : 1.0, 1.5 mm
• Bleeding air
a Bleed the air.
ING, Bleeding air.

PC750, 800-7 30-127

(2)
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY

LOADING SHOVEL
REMOVAL 5. Disconnect bottom dump cylinder hose (3),

1. Remove arm assembly. bucket cylinder hose (4), and arm cylinder hose
For details, see REMOVAL OF ARM ASSEM- (5).
BLY. a When the hoses are disconnected, oil may
spurt out, so loosen the hose flanges slowly
2. Sling bucket cylinder assembly (1), remove before disconnecting.
plate, then pull out pin (2), and remove bucket
cylinder assembly.
4 Pin: 35 kg
4 Bucket cylinder assembly: 555 kg
a Remove the bucket cylinder on the other

side in the same way.
6. Disconnect head lamp wiring.
7. Remove cover (6), and disconnect wiring (7) of

potentiometer and cable (8).
3. Sling boom, set stand at tip of boom to sup-

port boom.
8. Remove 3 mounting bolts (9), then remove

potentiometer assembly (10) together with
bracket (11).
4. Remove boom cylinder from boom.

For details, see REMOVAL OF BOOM CYLIN-
DER ASSEMBLY.
a Remove the boom cylinder on the other side
from the boom in the same way.
30-128 PC750, 800-7

(2)
9. Using forcing screws (Thread dia. = 16 mm, INSTALLATION

Pitch = 2.0 mm), pull out left and right boom foot • Carry out installation in the reverse order to
pins (12), then lift off boom (13). removal.
4 Boom: 4,490 kg k When aligning the mounting position of the


fied level.
PC750, 800-7 30-129

(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL AND INSTALLATION OF WORK EQUIPMENT

BACK HOE
SPECIAL TOOLS 4. Temporarily hang the work equipment assembly.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
790-445-4100 Remover t 1
Puller (294 kN
V 1 790-101-4200 t 1
{30 ton})
790-101-1102 Pump t 1
REMOVAL 5. Using the tool V1, remove the 2 pcs. of the

k Contract the arm and bucket cylinder piston boom foot pin (7).
rods, lower the work equipment to touch the a Since the shim is being installed, confirm the
ground completely and set the safety lock lever number of sheets and the position.
to the lock position.
a 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.
1. Referring to the section "Removal of the boom

cylinder assembly", separate the boom cylinder
assembly from the boom.
2. Separate the head lamp wire.
3. Separate the bucket cylinder hose (1) and the

arm cylinder hose (2). 6. Start the engine, back the machine slowly and
lower the boom foot section to touch the ground
using a crane.
k When backing the machine, confirm that the
boom foot section is completely separated
from the machine body side before starting
backing of the machine.
4 Work equipment assembly:

16,900 kg (PC750 STD)
18,300 kg (PC800 STD)
17,700 kg (PC750SE)
18,200 kg (PC800SE)
30-130 PC750, 800-7

(2)
INSTALLATION
2 To the inner surface of the bushing

when assembling the pin:
2 Greasing after assembling the pin:

Anti-friction material (LM-P)
Grease (LM-G)
k When matching the position of the pin hole,
never insert finger into the pin hole.
a Make adjustment so that the clearance a 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
a Carry out air bleeding referring to the section
"Air bleeding of each section" in the "Testing
and adjusting".

oil level.
PC750, 800-7 30-131

(2)
REMOVAL AND INSTALLATION OF WORK EQUIPMENT

LOADING SHOVEL
REMOVAL 3. Disconnect head lamp wiring.

k Retract the boom cylinder fully, extend the arm
cylinder, set the bottom of the bucket horizontal, 4. Remove potentiometer assembly.
then lower the work equipment completely to the For details, see REMOVAL OF BOOM ASSEM-
ground and stop the engine. BLY.
Operate the control levers several times to re-
lease the remaining pressure in the hydraulic 5. Set bottom of bucket horizontal, lower work
piping. Then loosen the oil filler cap slowly to re- equipment completely to ground, then sling
lease the pressure inside the hydraulic tank. boom assembly (4).
a Release the remaining pressure in the circuit.
Releasing pressure in hydraulic circuit.
1. Disconnect boom cylinder from boom.

For details, see REMOVAL OF BOOM CYLIN-
DER ASSEMBLY.
2. Disconnect bottom dump cylinder hose (1),

bucket cylinder hose (2), and arm cylinder hose
(3).
a When the hoses are disconnected, oil may
spurt out, so loosen the hose flanges slowly
before disconnecting. 6. Using forcing screws (Thread dia. = 16 mm,
k To prevent oil from spurting out when the Pitch = 2.0 mm), pull out left and right boom foot
engine is started, fit blind plugs securely in pins (5), then disconnect work equipment
the piping at the chassis end. assembly.
7. Start engine, drive machine slowly in reverse,

and operate crane to lower boom foot to ground.
k Before driving the machine in reverse,
check that the boom foot is completely sep-
4 Work equipment assembly:16,200 kg

arated from the machine body.
30-132 PC750, 800-7

(2)
INSTALLATION
removal.

a 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, 800-7 30-133

(2)
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY

REMOVAL 6. Remove left cover (7).
k Disconnect the cable from the negative (–) ter-
minal of the battery. 7. Disconnect center cover (8) and right cover (9).
1. Remove floor mat.
2. Remove operator’s seat (1).

a Be careful not to damage the cover.
8. Remove the cover (10) and duct (11).
CEP00438
11
3. Remove knob (2).
4. Remove 4 bolts and 1 clip, then remove panels

(3) and (4).
10
CEP00443
9. Separate the wiring intermediate connectors.

a For intermediate section of the harness
: CN-A11
: CN-A12
: CN-A13
: CN-A14
: CN-H10
: CN-H11
5. Disconnect hose (5) for window washer. : CN-H12
: CN-H15
: CN-M72
a For speaker : CN-M13
: CN-M73
a For air conditioner : CN-AC1
: CN-AC2
30-134 PC750, 800-7

(2)
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
10. Remove the 4 pcs. of the mounting nuts and the INSTALLATION
6 pcs. of the mounting bolts and hang the opera- • Installation shall be made in the reversed proce-
tor’s cab assembly to remove the operator’s dure of the removal procedure.
cab.
4 Operator’s cab: 300 kg (PC750) 3 Mounting nut:

350 kg (PC800) 276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
• The mark shows the nut and the e mark
shows the bolt.
a Regarding the bolt, confirm the length in ad-
vance.
CEP00445
PC750, 800-7 30-135

(2)
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS

(STUCK GLASS)
a Among the panes of window glass on the 4 sides (1) : Right side window glass
of the operator's cab, 4 panes (1) – (4) are stuck. (2) : Left side rear window glass
In this section, the procedure for replacing the (3) : Door lower window glass
stuck glass is explained. (4) : Front window glass
When replacing front window glass (4), remove (5) : Front window assembly
front window assembly (5). (It is impossible to (Front window glass + Front frame)
replace only the front window glass while the (6) : Both-sided adhesive tape
front window assembly is installed to the opera- (16): Center trim seal
tor's cab.)
For the procedure for replacing the front window
assembly, see REMOVAL AND INSTALLATION
OF FRONT WINDOW ASSEMBLY.
30-136 PC750, 800-7

(2)
SPECIAL TOOLS (The figure shows the operator's cab of a

wheel loader.)
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
Lifter
1 793-498-1210 t 2
Y (Suction cup)
2 20Y-54-13180 Adapter t 2
REMOVAL
a Remove the window glass to be replaced ac-
cording to the following procedure.
a If the window glass is broken finely, it may be
removed with knife [4] and a screwdriver.
1. Using seal cutter [1], cut the adhesive between
a Widening the cut with a screwdriver, cut the
broken window glass (7) and operator's cab
adhesive and both-sided adhesive tape with
(metal sheet) (8).
knife [4].
(The figure shows the operator's cab of a

wheel loader.)
a If a seal cutter is not available, make holes

on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
2. Remove the window glass.
both ends of the wire with priors [3], etc. (or
hold them by winding them onto something)
and move the wire to the right and left to cut
the adhesive and both-sided adhesive tape.
Since the wire may be broken by the friction-
al heat, apply lubricant to it.
PC750, 800-7 30-137

(2)
INSTALLATION 3. Apply primer (10).

1. Using a knife and scraper [5], remove the a The using limit of primer (10) is 4 months af-
remaining adhesive and both-sided adhesive ter the date of manufacture. Do not use prim-
tape from the metal sheets (glass sticking sur- er (10) after this limit.
faces) of the operator's cab. a Use the primer within 2 hours after unpack-
a Remove the adhesive and both-sided adhe- ing it.
sive tape to a degree that they will not affect a Even if the primer is packed again just after
adhesion of the new adhesive. Take care it is unpacked, use it within 24 hours after it
not to scratch the painted surfaces. (If the is unpacked for the first time. (Discard the
painted surfaces are scratched, adhesion primer 24 hours after it is packed.)
will be lowered.) 1) Stir the primers for paint and glass suffi-
ciently before using them.
(The figure shows the operator's cab of a a If the primer has been stored in a refrig-
wheel loader.) erator, leave it at the room temperature
for at least half a day before stirring it. (If
the primer is unpacked just after taken
out of the refrigerator, water will be con-
densed. Accordingly, leave the primer at
the room temperature for a sufficient
time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again
for dirt and foreign matter.
a Prepare respective brushes for the paint
primer glass primer.
2. Remove oil, dust, dirt, etc. from the sticking sur-

faces of cab (8) and window glass (9) with white
gasoline.
a If the sticking surfaces are not cleaned well,
the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
(The figure shows the operator's cab of a

wheel loader.)
30-138 PC750, 800-7

(2)
3) Evenly apply paint primer to the surfaces to a In addition to the above parts, apply the
stick both-sided adhesive tapes and the sur- primer to right side window glass (1) and
faces out of those surfaces on operator's door lower window glass (3).
cab (8) which will be coated with the adhe- • Range to apply primer additionally for
2 Paint primer:
sive. right side window glass (1): (b)
• Range to apply primer additionally for
SUNSTAR PAINT PRIMER door lower window glass (3): (c)
580 SUPER or equivalent a After applying the primer, leave it for at
a Do not apply the primer more than 2 least 5 minutes (within 8 hours) to dry.
times. (If it is applied more than 2 times,
its performance will be lowered.)
a Parts to be coated with primer: Apply the

primer all over dimension (a).
• Dimension to apply primer (a): 25 mm
a Never apply wrong primer. If the glass

primer is applied by mistake, wipe it off
with white gasoline.
PC750, 800-7 30-139

(2)
4) Evenly apply glass primer to the sticking 4. Stick both-sided adhesive tape (6) along the
2 Glass primer:
surfaces of window glass (9). inside edge of the glass sticking section.
a Do not remove the release tape of the both-
SUNSTAR GLASS PRIMER sided adhesive tape on the glass sticking
580 SUPER or equivalent side before sticking the glass.
a Do not apply the primer more than 2 a When sticking the both-sided adhesive tape,
times. (If it is applied more than 2 times, do not touch the cleaned surface as long as
its performance will be lowered.) possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window frame.
a Parts to be coated with primer: Apply the

primer to the sticking surfaces of window
glass (9) and all over dimension (d) a When sticking both-sided adhesive tape (6)
which will be on both-sided adhesive around a frame, do not lap its finishing end
tape (6) and operator's cab (8). over the starting end but make clearance e of
a Do not apply the primer to the boarder about 5 mm between them.
about 5 mm wide between the black part 1) Stick both-sided adhesive tape (6) for right
and transparent part of the glass. side window glass (1) as shown in the fig-
a After applying the primer, leave it for at ure.
least 5 minutes (within 8 hours) to dry.
a Never apply wrong primer. If the glass
primer is applied by mistake, wipe it off
with white gasoline.
30-140 PC750, 800-7

(2)
a Stick both-sided adhesive tape (6a) addition- a Stick both-sided adhesive tape (6b) ad-
ally for right side window glass (1). ditionally for door lower window glass
• Positions to stick additional both-sided adhe- (3).
sive tape for right side window glass: a Positions to stick additional both-sided
(f) : 50 mm adhesive tape for door lower window
(g) : 90 mm glass:
(h) : 250 mm (j) : 110 mm
(k) : 90 mm
(m) : 200 mm
2) Stick both-sided adhesive tape (6) for left

side rear window glass (2) as shown in the
figure. 4) Stick both-sided adhesive tape (6) for front
window glass (4) as shown in the figure.
3) Stick both-sided adhesive tape (6) for door

lower window glass (3) as shown in the fig- a Stick both-sided adhesive tape (6c) of
ure. the lower side of the front window glass
along the outside edge of the lower line,
differently from other both-sided adhe-
sive tapes (6). (If it is stuck along the in-
side, it will be seen through the
transparent part of the glass.)
PC750, 800-7 30-141

(2)
5. Position the new window glass. a When positioning front window glass (4),
1) Check the clearance between the window set its horizontal position to the frame
glass and the operator's cab on the right, width and set its vertical position so that
left, upper, and lower sides, and then adjust height difference (p) between it and the
it evenly. frame top will be 3 mm.
2) Stick tapes [6] between window glass (9)
and operator's cab (8) and draw positioning
line n.
a Stick tapes [6] to the right, left, and lower
parts of the right side window glass, left
side rear window glass, and door lower
window glass for accurate positioning.
3) Cut the tape between window glass (9) and
operator's cab (8) with a knife, and then
remove the window glass.
a Do not remove the tapes left on the win-
dow glass and operator's cab before in-
stalling the window glass.
6. Apply adhesive.
2 Adhesive (Summer):
a Use either of the 2 types of the adhesive.
SUNSTAR PENGUINE
2 Adhesive (Winter):
SEAL 580 SUPER "S"
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use the
adhesive after this limit.
a Keep the adhesive in a dark place where the
temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
1) Break aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the noz-
zle.
30-142 PC750, 800-7

(2)
2) Cut the tip of the adhesive nozzle (14) so a Apply adhesive (15) to dimensions (s)
that dimensions (q) and (r) will be as fol- and (t) of both-sided adhesive tape (6) of
lows. operator's cab (8).
• Dimension (q): 10 mm • Dimension (s) : 10 mm
• Dimension (r) : 15 mm • Dimension (t) : 15 mm
a Apply adhesive (15) higher than both-
sided adhesive tape (6).
a Apply the adhesive evenly.
3) Set adhesive cartridge (12) to caulking gun

[7].
a An electric caulking gun is more efficient.
a Apply adhesive (15) additionally for ad-
ditional both-sided adhesive tape (6a) of
the right side window glass and addition-
al both-sided adhesive tape (6b) of door
lower window glass.
4) Remove the release tape of the both-sided

adhesive tape on the glass side.
5) Apply adhesive (15) to the outside of both-
sided adhesive tape (6) of the operator's
cab.
PC750, 800-7 30-143

(2)
7. Install the window glass. a After installing front window glass (4), fill
1) Install window glass (9), matching it to the the clearances between it and center
lines of the positioning tapes drawn in step trim seal (16) with caulking material in
5. range (s) to dimensions (t) and (u).
a Since the window glass cannot be re- After applying the primer to glass (4) of
moved and stuck again, stick it very section A – A, apply adhesive as caulk-
carefully. ing material.
a Stick the glass within 5 minutes after ap- • Caulking dimension (t) : 2 mm
plying the adhesive. • Caulking dimension (u) : 5 mm
2) After sticking window glass (9), press all a When caulking, mask the glass side and
around it until it is stuck to the both-sided form the adhesive with a rubber spatula
adhesive tape. as shown in the figure.
2 Glass primer:
a Press the corners of the window glass a Wipe off projected adhesive.
firmly.
SUNSTAR GLASS
2 Adhesive:
PRIMER 580 SUPER
SUNSTAR PENGUINE
SEAL 580 SUPER "S" or "W"
a You can perform this work efficiently by

pulling window glass (9) from inside of
the operator's cab with suction cup Y1.
30-144 PC750, 800-7

(2)
8. Fix the window glass. 9. After installing the window glass, remove the
1) After installing right window glass (1) to the primer and adhesive from the operator's cab
operator's cab, insert stopper rubbers Y2 to and window glass.
2 places (v) at the bottom of the glass to fix a Using white gasoline, wipe off the adhesive
the glass. before it is dried up.
a When cleaning the glass, do not give an im-
pact to it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humidity
of 60%).
2) After removing the stopper rubbers, styrene
foam blocks, and rubber bands, wait at least
14 hours, at least 24 hours in total, before
operating the machine actually.
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and both-
sided adhesive tape to fit them completely.
PC750, 800-7 30-145

(2)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY

k Lower the work equipment to the ground and 5. Release the rear locks.
stop the engine.
a To replace the front window glass, the front win- 6. Lower the front window assembly carefully a lit-
dow assembly must be removed from the opera- tle. Put out rollers (8) and (9) under the both
tor's cab. The procedure for removing and sides of the front window through the portion
installing the front window assembly (front frame from which the corner blocks were removed in
and front window glass) is explained below. step 3 (the portion where the rail is open) and
hold them.
REMOVAL
1. Raise the front window assembly to the ceiling 7. Remove rollers (8) and (9) under the both sides
and fix it with the rear locks (on both sides). of the front window.
2. Remove left corner blocks (1) and (2) and right

corner block (3).
3. Remove left striker bolt (4), right striker bolt (5),

left corner block bracket, and right corner block
bracket (7).
4. Install left striker bolt (4) to the operator's cab

again and tighten it lightly.
a This bolt will be used to hang the pull-up as-
sist cable in step 8.
30-146 PC750, 800-7

(2)
8. Remove left lower pin (10). 10. Lower front window assembly (13) completely.
a If left lower pin (10) is removed, plate (12) at a Do not let the front window assembly touch
the end of pull-up assist cable (11) comes the monitor.
off.
a Hang plate (12) on the left striker bolt.
k The return load of 58.8 N {6 kg} is applied to
the rear of the operator's cab. Accordingly,
take care when removing left lower pin (10)
to disconnect pull-up assist cable (11).
11. Twist front window assembly (13) to the right

and left to remove both upper rollers (14) and
(15) from the rails, and then remove front win-
dow assembly (13).
9. Put out the bottom of front window assembly

(13) through the rail opening portion and lower it
gradually.
PC750, 800-7 30-147

(2)
INSTALLATION

removal.
• Adjust opening and closing of the front window

assembly according to the following procedure.
1. 1.Open and close the front window to check that

it does not interfere with the rails and the rollers
are not hitch.
2. If there is any problem in opening or closing of

the front window, loosen the mounting bolts of
roller adjustment brackets (16) and (17) and
adjust the condition of the front window, and
3 Mounting bolt: 98 Nm {1.0 kgm}

then tighten the mounting bolts again.
30-148 PC750, 800-7

(2)
3. Raise the front window assembly and fix it with 5. Install left corner blocks (1) and (2) and secure
the rear locks (on both sides). left corner bracket (6) with left striker bolt (4).
a Check that the locks in the rear of the opera- a Tighten the striker bolt securely after adjust-
tor's cab are applied securely. ing it in step 6.
a Install the left corner blocks so that there will
4. Install right corner block (3) and fix right corner be no level difference at 2 part (d).
block bracket (7) with right striker bolt (5). a Secure roller clearance (e).
a Tighten the striker bolt securely after adjust-
ing it in step 6.
a Install the right corner block so that there will
be no level difference at part (a).
a Install the right corner block so that level dif-
ference (b) between the rail and right corner
block (3) at part PF will be 0 – 1.0 mm.
Check that the right corner block is not pro-
jected from the rail at the rolling surface of
the roller.
a Secure roller clearance (c) at part PJ.
PC750, 800-7 30-149

(2)
6. Tighten left striker bolt (4) and right striker bolt 7. Open and close the front window assembly and
(5) at roughly right positions so that front window check the working condition of both locks (20)
glass (18) will be fitted to cab-side trim seal (19). and (21).
1) If both locks do not work normally, move the
striker bolts toward the rear of the cab and
tighten them again.
2) After moving the striker bolts, check the fit-
ness of the front window glass and cab-side
trim seal which was checked in step 6.
3) Repeat the work in 1) and 2) until the fitness
of the front window and the working condi-
tion of both locks (20) and (21) are accepta-
ble, and then tighten the striker bolts.
8. After adjusting the striker bolts, splash water

heavily over the front window glass and check
that the water does not leak into the cab.
9. Adjust the "opening" lock of the front window

assembly.
1) After adjusting the "closing" lock of the front
window in steps 6 and 7, raise the front win-
dow assembly to the ceiling.
2) Check the working condition of both front
window assembly "opening" locks in the
rear of the operator's cab.
3) If the locks do not work normally, move both
striker plates (22) in the rear of the opera-
tor's cab forward and in reverse and fix them
at places where the locks work normally.
30-150 PC750, 800-7

(2)
10. Adjust the front window stoppers.

1) After adjusting "closing" lock of the front
window assembly in step 9, check the con-
tact of both front window stoppers (23).
2) If both stoppers (23) do not contact nor-
mally, adjust and fix them at places where
they contact normally.
11. Check the latching effort of the front window

assembly.
1) After finishing steps 6 – 10, check that latch-
ing efforts of both locks (20) and (21) are
even.
a Check the latching efforts on both "clos-
ing" side (in the front of the operator's
cab) and "opening" side (in the rear of
the operator's cab).
3 Left lower pin:

27 – 34 Nm {2.75 – 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
PC750, 800-7 30-151

(2)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY

1. Set chain to lifting hook of counterweight • Carry out installation in the reverse order to
assembly, and sling. removal.
2. Remove mounting bolts (1).

a Adjust the stepped difference (top and bot-
tom clearance) from the bodywork with
shims.
a Install so that the clearance between the
counterweight and the revolving frame is 15
mm, and so that the stepped difference is
3 Counterweight mounting bolt:

uniform on the left and right.
3,822 ± 392 Nm {390 ± 40 kgm}
3. Lift off counterweight assembly (2).
4 Counterweight assembly:
12,000 kg (PC800)
9,800 kg (PC750)
30-152 PC750, 800-7

(2)
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................90- 3

PC750-7, PC750SE-7
PC800-7, PC800SE-7
HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................90- 5
PC750-7, PC750SE-7
ELECTRICAL CIRCUIT DIAGRAM (1/6) ......................................................................................................90- 7
PC750-7, PC750SE-7
PC800-7, PC800SE-7
PC750-7, PC750SE-7
PC800-7, PC800SE-7
PC750-7, PC750SE-7
PC800-7, PC800SE-7
PC750-7, PC750SE-7
PC800-7, PC800SE-7
PC750-7, PC750SE-7
PC800-7, PC800SE-7
PC750-7, PC750SE-7
PC750, 800-7 90-1

(3)
HYDRAULIC CIRCUIT DIAGRAM
PC750-7, PC750SE-7
PC800-7, PC800SE-7
PC750, 800-7 90-3

(3)
HYDRAULIC CIRCUIT DIAGRAM
PC750-7, PC750SE-7
PC750, 800-7 90-5

(3)
ELECTRICAL CIRCUIT DIAGRAM (1/6)
PC750-7, PC750SE-7
PC800-7, PC800SE-7
PC750, 800-7 90-7

(3)
PC750-7, PC750SE-7
PC800-7, PC800SE-7
PC750, 800-7 90-9

(3)
PC750-7, PC750SE-7
PC800-7, PC800SE-7
PC750, 800-7 90-11

(3)
PC750-7, PC750SE-7
PC800-7, PC800SE-7
PC750, 800-7 90-13

(3)
PC750-7, PC750SE-7
PC800-7, PC800SE-7
PC750, 800-7 90-15

(3)
PC750-7, PC750SE-7
PC750, 800-7 90-17

(3)

PC750-7 Shop Manual PDF

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PC750-7 Shop Manual PDF

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SEBM031303

MACHINE MODEL SERIAL No.

• PC750, 800-7 mounts the SAA6D140E-3 engine.

10 STRUCTURE, FUNCTION AND

20 TESTING AND ADJUSTING ........................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

90 OTHERS ................................................................................................................................ 90-1

00-2 PC750, 800-7

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 PAGES

Time of Time of Time of Time of Time of

00-1 (3) 01-1 10-10 10-37 10-68

PC750, 800-7 00-2-1

Time of Time of Time of Time of Time of

00-2-2 PC750, 800-7

Time of Time of Time of Time of Time of

PC750, 800-7 00-2-3

Time of Time of Time of Time of Time of

00-2-4 PC750, 800-7

Time of Time of Time of Time of Time of

PC750, 800-7 00-2-5

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

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• 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

k Before carrying out the following work, release Type 1

k 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, rub-

Holtz • Used as heat-resisting sealant for re-

• Used as lubricant for sliding portion

SYG2-400CA • Used for normal temperature, light

Molybdenum • Used for heavy load portion

SUNSTAR • Used as primer for cab side

• "S" is used for high-tempera-

SUNSTAR • Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS