This Complete Service Repair Workshop Manual PDF Download for the Komatsu PC75UU-2 Hydraulic Excavator (5001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Komatsu PC75UU-2 - S/N: 5001 and up
TABLE OF CONTENTS :
01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM001302
Total Pages : 391
This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.
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CONTENTS
01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND WATER
10 STRUCTURE AND FUNCTION
HYDRAULIC PIPING DIAGRAM
HYDRULIC CIRCUIT DIAGRAM
ELECTRIC WIRING DIAGRAM
ELECTRIC CIRCUIT DIAGRAM
20 TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TOOLS FOR TESTING ,ADJUSTING,AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING ENGINE OIL PRESSURE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY
ADJUSTING VALVE CLEARANCE
TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION
ADJUSTING FUEL CONTROL LEVER
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING CONTROL CIRCUIT PRESSURE
MEASURING OUTPUT PRESSURE OF PPC VALVE
ADJUSTING PPC VALVE
MEASURING OUTLET PORT PRESSURE OF SOLENOID VALVE,EPC VALVE
MEASURING OIL LEAKAGE INSIDE CYLINDER
MEASURING OIL LEAKAGE FROM SWING,TRAVEL MOTOR
BLEEDING AIR FROM HYDRAULIC CIRCUIT
RELEASING REMAINING FROM HYDRAULIC CIRCUIT
ADJUSTING BLADE CONTROL LEVER
ADJUSTING TRAVEL CONTROL LEVER
PROCEDURE FOR RESETTING ELECTRICAL SYSTEM INPUT/OUTPUT SIGNALS AND CHECKING OPERATION
PROCEDURE FOR REPLACING POTENTIOMETER
PROCDURE FOR CHECKING DIODE
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
CONNECTOR ARRANGEMENT DRAWING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
HANDING CONNECTORS
EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM
DISPLAY METHOD FOR MONITOR PANEL,CONTROLLER
ACTION TAKEN BY SELF DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE
METHOD OF USING JUDGEMENT TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF CONTROLLER,ELECTRICAL SYSTEM (E MODE)
JUDGEMENT TABLE FOR CONTROLLER,ELECTRICAL,HYDRAULIC AND MECHANICAL SYSTEMS
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM
PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS
E-1 ERROR CODE [EE] (ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM OR COMMUNICATIONS SYSTEM)
a) ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM
b) ABNORMALITY IN COMMUNICATIONS SYSTEM
E-2 ERROR CODE [21] (ABNORMALITY IN MODEL SELECTION SYSTEM)
E-3 ERROR CODE [22] (ABNORMALITY IN WORK EQUIPMENT SELECTION SYSTEM)
E-4 ERROR CODE [31] (ABNORMALITY IN BOOM POTENTIOMETER SYSTEM)
E-5 ERROR CODE [32] (ABNORMALITY IN ARM POTENTIOMETER SYSTEM)
E-6 ERROR CODE [34] (ABNORMALITY IN OFFSET POTENTIOMETER SYSTEM)
E-7 ERROR CODE [41] (ABNORMALITY IN PPC LOCK SOLENOID SYSTEM)
E-8 ERROR CODE [42] (ABNORMALITY IN LEFT OFFSET STOP SOLENOID SYSTEM)
E-9 ERROR CODE [44] (ABNORMALITY IN BOOM LOWER STOP SOLENIOD SYSTEM)
E-10 ERROR CODE [51] (ABNORMALITY IN BOOM RAISE STOP SOLENOID SYSTEM)
E-11 ERROR CODE [52] (ABNORMALITY IN ARM IN STOP SOLENOID SYSTEM)
E-12 WORK EQUIPMENT DOES NOT WORK EVEN WHEN EQUIPMENT LOCK LEVER IS RELEASED
E-13 DEPTH MODE,HEIGHT MODE,OFFSET MODE DO NOT WORK PROPERLY (GO BEYOND SET POSITION BEFORE STOPPING OR STOP BEFORE REACHING SET POSITION)
E-14 IMPOSSIBLE TO SELECT AND SET DEPTH DISPLAY 0 SET MODE,DEPTH MODE,HEIGHT MODE,OFFSET MODE
E-15 CANCLE SWITCH IS NOT TURNED ON,BUT ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRIC SYSTEM CAUTION LAMP FLASHES
E-16 AUTOMATIC STOP IS NOT CARRIED OUT FOR BOOM RAISE,ARM IN,LEFT OFFSET (WHEN ERROR CODE [61] IS NOT DISPLAYED)
E-17 WORK EQUIPMENT LOCK LEVER IS AT LOCK POSITION BUT WORK EQUIPMENT MOVES
E-18 ENGINE DOES NOT START WHEN STARTING SWITCH IS TURNED TO START
E-19 EVEN WHEN STARTING SWITCH IS TURNED OFF,ENGINE DOES NOT STOP
E-20 UPPER STRUCTURE DOES NOT SWING (WHEN SWING LEVER IS OPERATED,AND NO ELECTRICITY FLOWS TO SWING BRAKE SOLENOID)
E-21 EXCESSIVE HYDRAULIC DRIFT OF SWING (WHEN ELECTRIC CURRENT FLOWS TO SWING BRAKE SOLENIOD BOTH WHEN SWING LEVER IS OPERATED AND AT NEUTRAL)
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)
H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW
a) SPEEDS OF ALL WORK EQUIPMENT AND SWING ARE SLOW (WHEN BLADE AND TRAVEL SPEEDS ARE NORMAL)
b) SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE ALL SLOW
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS
H-3 NO WORK EQUIPMENT,SWING,TRAVEL MOVE
a) NONE OF WORK EQUIPMENT AND SWING MOVE
b) NONE OF WORK EQUIPMENT, SWING, TRAVEL MOVE
H-4 ALL WORK EQUIPMENT,SWING,TRAVEL LACK POWER
H-5 ABNORMAL NOISE GENERATED FROM AROUND PUMP
H-6 WORK EQUIPMENT SPEED IS SLOW (ONE OF BOOM,ARM,BUCKET,OFFSET IS SLOW)
H-7 WORK EQUIPMENT LACKS POWER (ONE OF BOOM,ARM,BUCKET,OFFSET LACKS POWER)
H-8 WORK EQUIPMENT DOES NOT MOVE (ONE OF BOOM,ARM,BUCKET,OFFSET DOES NOT MOVE)
H-9 EXCESSIVE HYDRAULIC DRIFT
H-10 EXCESSIVE TIME LAG
H-11 WHEN MACHINE IS TRAVELING,IT DEVIATES NATURALLY TO ONE SIDE
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE
H-12 EXCESSIVE DEVIATION WHEN STARTING
H-13 TRAVEL LACKS POWER (OR SPEED IS SLOW)
H-14 TRACK DOES NOT MOVE (ONE SIDE ONLY)
H-15 TRAVEL LEVER IS HEAVY
H-16 DOES NOT SWING
H-17 SWING SPEED IS SLOW OR ACCELERATION IS POOR
H-18 EXCESSIVE OVERRUN WHEN STOPPING SWING
H-19 EXCESSIVE SHOCK WHEN STOPPING SWING
H-20 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING
H-21 EXCESSIVE HYDRAULIC DRIFT OF SWING
H-22 ERROR CODE [61] IS DISPLAYED ON MONITOR PANEL,AND JUST BEFORE INTERFERENCE,BOOM RAISE,ARM IN,AND LEFT OFFSET ALL STOP
H-23 BOOM RAISE,ARM IN,AND LEFT OFFSET DO NOT AUTOMATICALLY STOP AND THERE IS INTERFERENCE
TABLE OF FAILURE MODES AND CAUSES
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)
M-1 WHEN THE STARTING SWITCH IS TURNED ON,NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS)
M-2 WHEN STARTING SWITCH IS TURNED ON,LAMPS LIGHT UP FOR 3 SECONDS,BUT THEN DO NOT GO OUT
M-3 WHEN STARTING SWITCH IS TURNED ON,SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS
a) NO GAUGE LAMPS LIGHT UP PREHEATING PILOT DOES NOT LIGHT UP
b) BATTERY ELECTROLYTE LEVEL CAUTION LAMP DOES NOT LIGHT UP ,ELECTRIC SYSTEM CAUTION LAMP DOES NOT LIGHT UP
c) CHARGE CAUTION LAMP DOES NOT LIGHT UP
d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP
M-4 WHEN STARTING SWITCH IS ON (ENGINE STOPPED),CHARGE CAUTION LAMP DOES NOT LIGHT UP
M-5 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP
M-6 DURING PREHEATING,PREHEATING PILOT LAMP DOES NOT LIGHT UP
M-7 WHEN STARTING SWITCH IS ON (ENGINE STOPPED),BATTERY ELECTROLYTE LEVEL CAUTION LAMP LIGHTS UP (BATTERY ELECTROLYTE IS AT SPECIFIED LEVEL)
M-8 WHEN ENGINE IS RUNNNG,ENGINE OIL PESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL)
M-9 WHEN ENGINE IS RNNING,CHARGE CAUTION LAMP LIGHTS UP
M-10 ABNORMALITY DISPLAY ON COOLANT TEMPERATURE GAUGE
a) AFTER ENGINE IS STARTED,LEVEL STAYS AT BOTTOM AND DOES NOT MOVE
b) AFTER ENGINE IS STARTED,LEVEL IMMEDIATELY RISES, ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE
M-11 ABNORMALITY DISPLAY ON FUEL GAUGE
a) ALL FUEL GAUGE SEGMENTS GO OUT
b) EVEN WHEN FUEL LEVEL GOES DOWN,FUEL GAUGE CONTINUES TO SHOW FULL
c) EVEN WHEN TANK IS FILLED,FUEL GAUGE DOES NOT SHOW FULL
M-12 DEFECTIVE OPERATION OF ALARM BUZZER
a) BUZZER DOES NOT SOUND
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP
M-13 WHEN ENGINE IS RUNNING,SERVICE METER DOES NOT ADVANCE
a) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP
b) WHEN CHARGE CAUTION LAMP LIGHTS UP
M-14 NIGHT LINGHTING DOES NOT LIGHT UP
a) LIGHTING OF COOLANT TEMPERATURE GAUGE,FUEL GAUGE,DEPTH DISPLAY DOES NOT LIGHT UP
b) LIGHTING OF SERVICE METER DOES NOT LIGHT UP
M-15 ELECTRIC SYSTEM CAUTION LAMP STAYS LIGHTED UP,AND DOES NOT GO OUT (NO ABNORMALITY DISPLAY ON CONTROLLER,OPERATION IS NORMAL)
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOLS LIST
SCHEMATIC DRAWING OF SPECIAL TOOL
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP
REMOVAL AND INSTALLATION
WATER PUMP
REMOVAL
INSTALLATION
NOZZLE HOLDER
REMOVAL AND INSTALLTION
THERMOSTAT
REMOVAL AND INSTALLATION
ENGINE FRONT SEAL
REMOVAL AND INSTALLATION
ENGINE REAR SEAL
REMOVAL AND INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
HYDRAULIC OIL COOLER
REMOVAL AND INSTALLATION
RADIATOR
REMOVAL AND INSTALLATION
ENGINE AND MAIN PUMP
REMOVAL
INSTALLATION
DAMPER
REMOVAL AND INSTALLATION
CENTER SWIVEL JOINT
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
REMOVAL AND INSTALLATION
SPROCKET
REMOVAL AND INSTALLATION
SWING MOTOR AND SWING MACHINERY
REMOVAL AND INSTALLATION
SWING MOTOR
DISASSEMBLY
ASSEMBLY
SWING MACHINERY
DISASSEMBLY
ASSEMBLY
REVOLVING FRAME
REMOVAL
INSTALLATION
SWING CIRCLE
REMOVAL AND INSTALLATION
IDLER AND RECOIL SPRING
REMOVAL AND INSTALLATION
IDLER
DISASSEMBLY
ASSEMBLY
RECOIL SPRING
DISASSEMBLY
ASSEMBLY
TRACK ROLLER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
RUBBER SHOE
REMOVAL AND INSTALLATION
STEEL SHOE AND ROAD LINER
EXPANSION AND INSTALLATION
PPC PUMP
REMOVAL AND INSTALLATION
MAIN PUMP
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
3-SPOOL CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
4-SPOOL CONTROL VALVE
REMOVAL
INSTALLATION
MAIN RELIEF VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
PPC VALVE ASSEMBLY ON LEFT SIDE OF WORK EQUIPMENT
REMOVAL AND INSTALLATION
PPC VALVE ON RIGHT SIDE OF WORK EQUIPMENT
REMOVAL AND INSTALLATION
WORK EQUIPMENT PPC VALVE
DISASSEMBLY
ASSEMBLY
PPC VALVE FOR OFFSET OPERATION
REMOVAL AND INSTALLATION
ARM CYLINDER
REMOVAL
INSTALLATION
BUCKERT CYLINDER
REMOVAL
INSTALLATION
BOOM CYLINDER
REMOVAL
INSTALLATION
OFFSET CYLINDER
REMOVAL
INSTALLATION
BLADE CYLINDER
REMOVAL
INSTALLATION
HYDRAULIC CYLINDER
DISASSSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL
INSTALLATION
BUCKET
REMOVAL AND INSTALLATION
ARM
REMOVAL
INSTALLATION
2ND BOOM
REMOVAL
INSTALLATION
BUCKET AND ARM
REMOVAL
INSTALLATION
1ST BOOM
REMOVAL
INSTALLATION
BLADE
REMOVAL AND INSTALLATION
OPERATOR'S CAB
REMOVAL AND INSTALLATION
FLOOR FRAME
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL AND INSTALLATION
CONTROLLER
REMOVAL AND INSTALLATION
MONITOR
REMOVAL AND INSTALLATION
COUNTERWEIGHT
REMOVAL AND INSTALLATION
40 MAINTENANCE STANDARD
SWING MACHINERY
SWING CIRCLE
TRACK FRAME,RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
SPROCKET
TRACK SHOE
HYDRAULIC PUMP
3-SPOOL CONTROL VALVE(FOR FRONT PUMP)
3-SPOOL CONTROL VALVE(FOR CENTER PUMP)
4-SPOOL CONTROL VALVE
SWING MOTOR
CENTER SWIVEL JOINT
PPC VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT
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