Komatsu Excavator PC600-8R1,PC600LC-8R1,PC700LC-8R Shop Manual PDF

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Komatsu Excavator PC600-8R1,PC600LC-8R1,PC700LC-8R Shop Manual –  PDF DOWNLOAD

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Komatsu Excavator PC600-8R1,PC600LC-8R1,PC700LC-8R Shop Manual –  PDF DOWNLOAD

Language : English
Pages : 1355
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Excavator PC600-8R1,PC600LC-8R1,PC700LC-8R Shop Manual –  PDF DOWNLOAD

• SERIAL NUMBERS 70001 and up

COVER . 1
Notice of revision 3
00 Index and foreword . 11
Table of Contents . 12
Foreword, safety and general information 22
Important safety notice . 22
How to read the shop manual . 29
Explanation of terms for maintenance standard . 31
Handling equipment of fuel system devices . 33
Handling of intake system parts . 34
Handling of hydraulic components 35
Method of disconnecting and connecting push-pull type coupler . 37
Handling of electric equipment 40
How to read electric wire code 49
Precautions when performing operation . 52
Practical use of KOMTRAX 55
Precautions when performing work 56
Standard tightening torque table 59
List of abbreviation 63
Conversion table 68
01 Specification 73
Contents 74
Specifications 76
Specifications drawing 76
Working range drawings 78
Specifications 80
Table of weight . 88
Table of fuel, coolant and lubricants . 94
10 Structure and function . 97
Contents 98
Engine and cooling system . 99
Engine related parts 99
PTO . 100
Cooling system 101
Power train system 102
Power train . 102
Swing circle 104
Swing machinery . 106
Final drive . 108
Undercarriage and frame . 110
Track frame and idler cushion . 110
Hydraulic system 112
Hydraulic component layout 112
Valve control . 114
Hydraulic tank and filter . 116
Hydraulic pump (piston pump) 118
Cooling fan pump 146
Cooling fan motor . 154
Control valve . 160
Swing motor . 176
Travel motor 184
PPC valve . 205
Solenoid valve 213
PPC shuttle valve . 220
Boom drift prevention valve . 221
Boom LOWER regeneration valve . 225
Arm regeneration valve 228
Quick return valve 231
Line oil filter . 234
Center swivel joint . 235
Accumulator . 236
Electrical system . 237
Engine control 237
Electrical control system . 245
Monitor system 275
KOMTRAX system 301
Sensors . 303
20 Standard value table . 307
Contents 308
Standard value table 309
Standard value table for engine . 309
Standard value table for machine 310
30 Testing and adjusting 333
Contents 334
Tool for testing, adjusting and troubleshooting . 335
Tools for testing, adjusting, and troubleshooting . 335
Engine and cooling system . 339
Testing engine speed 339
Testing intake air pressure (boost pressure) 341
Testing exhaust gas temperature . 342
Testing exhaust gas color . 343
Testing and adjusting valve clearance . 344
Testing compression pressure 345
Testing blowby pressure . 347
Testing engine oil pressure . 348
Handling fuel system parts 349
Releasing remaining pressure from fuel system . 350
Testing fuel pressure . 351
Cylinder cut-out test mode 352
No-injection cranking . 353
Testing fuel return rate and leakage 354
Bleeding air from fuel circuit 357
Testing fuel circuit for leakage 359
Testing and adjusting alternator belt tension . 360
Testing and adjusting air conditioner compressor belt tension . 361
Undercarriage and frame . 362
Testing swing circle bearing clearance 362
Checking and adjusting track tension 363
Hydraulic system 364
Testing and adjusting oil pressure in work equipment, swing and travel circuits . 364
Testing and adjusting control circuit oil pressure 369
Testing and adjusting control oil pressure of piston pump . 371
Testing servo piston movement . 377
Testing PPC valve output pressure . 378
Testing output pressure of solenoid valve and PPC shuttle valve . 382
Adjusting play of work equipment and swing PPC vavles . 388
Isolating the parts causing hydraulic drift in work equipment . 389
Testing and adjusting travel deviation 391
Testing fan speed . 393
Testing fan circuit oil pressure 394
Releasing remaining pressure from hydraulic circuit . 395
Testing oil leakage . 396
Bleeding air from each part . 400
Electrical system . 403
Special functions of machine monitor 403
Handling of voltage circuit of engine controller 447
Preparatory work for troubleshooting of electrical system . 448
Inspection procedure of diode . 453
Pm clinic . 454
Pm Clinic service . 454
UNDERCARRIAGE INSPECTION REPORT . 466
40 Troubleshooting 469
Contents 470
General information on troubleshooting 476
Points to remember when troubleshooting . 476
Sequence of events in troubleshooting . 477
Checks before troubleshooting . 478
Classification and procedures for troubleshooting . 502
Failure codes table . 505
Symptom and troubleshooting numbers . 509
Information in troubleshooting table 512
Troubleshooting method for open circuit in wiring harness of pressure sensor system . 514
Connector list and layout . 516
Connection table for connector pin numbers 526
T- branch box and T- branch adapter table . 562
Fuse locations 565
Troubleshooting by failure code . 568
Failure code [989L00] Engine Controller Lock Caution 1 568
Failure code [989M00] Engine Controller Lock Caution 2 569
Failure code [989N00] Engine Controller Lock Caution 3 570
Failure code [AA10NX] Air Cleaner Clogging 571
Failure code [AB00KE] Charge Voltage Low 572
Failure code [B@BAZG] Eng Oil Press Low . 574
Failure code [B@BAZK] Eng Oil Level Low . 575
Failure code [B@BCNS] Eng Water Overheat 576
Failure code [B@BCZK] Eng Water Level Low . 578
Failure code [B@HANS] Hyd Oil Overheat 580
Failure code [CA111] ECM Critical Internal Failure 582
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 584
Failure code [CA122] Chg Air Press Sensor High Error 586
Failure code [CA123] Chg Air Press Sensor Low Error . 588
Failure code [CA131] Throttle Sensor High Error . 590
Failure code [CA132] Throttle Sensor Low Error 592
Failure code [CA135] Eng Oil Press Sensor High Error 594
Failure code [CA141] Eng Oil Press Sensor Low Error . 596
Failure code [CA144] Coolant Temp Sens High Error . 598
Failure code [CA145] Coolant Temp Sens Low Error 600
Failure code [CA153] Chg Air Temp Sensor High Error . 602
Failure code [CA154] Chg Air Temp Sensor Low Error 604
Failure code [CA187] Sens Supply 2 Volt Low Error . 606
Failure code [CA221] Ambient Press Sens High Error 608
Failure code [CA222] Ambient Press Sens Low Error . 610
Failure code [CA227] Sens Supply 2 Volt High Error 612
Failure code [CA234] Eng Overspeed 613
Failure code [CA238] NE Speed Sens Supply Volt Error 614
Failure code [CA263] Fuel Temp Sensor High Error 616
Failure code [CA265] Fuel Temp Sensor Low Error . 618
Failure code [CA271] IMV/PCV1 Short Error . 620
Failure code [CA272] IMV/PCV1 Open Error 621
Failure code [CA273] PCV2 Short Error . 622
Failure code [CA274] PCV2 Open Error 623
Failure code [CA322] Inj #1(L#1) Open/Short Error . 624
Failure code [CA323] Inj #5 (L#5) Open/Short Error 626
Failure code [CA324] Inj #3(L#3) Open/Short Error . 628
Failure code [CA325] Inj #6 (L#6) Open/Short Error 630
Failure code [CA331] Inj #2(L#2) Open/Short Error . 632
Failure code [CA332] Inj #4 (L#4) Open/Short Error 634
Failure code [CA342] Calibration Code Incompatibility . 636
Failure code [CA351] Injectors Drive Circuit Error 637
Failure code [CA352] Sens Supply 1 Volt Low Error . 638
Failure code [CA386] Sens Supply 1 Volt High Error 640
Failure code [CA441] Battery Voltage Low Error 640
Failure code [CA442] Battery Voltage High Error . 641
Failure code [CA449] Rail Press Very High Error . 641
Failure code [CA451] Rail Press Sensor High Error . 642
Failure code [CA452] Rail Press Sensor Low Error 644
Failure code [CA553] Rail Press High Error 646
Failure code [CA554] Rail Press Sensor In Range Error . 646
Failure code [CA559] Supply Pump Press Low Error 1 647
Failure code [CA689] Eng NE Speed Sensor Error 650
Failure code [CA731] Eng Bkup Speed Sens Phase Error 652
Failure code [CA757] All Continuous Data Lost Error . 653
Failure code [CA778] Eng Bkup Speed Sensor Error 654
Failure code [CA1633] KOMNET Datalink Timeout Error . 656
Failure code [CA2185] Throt Sens Sup Volt High Error 658
Failure code [CA2186] Throt Sens Sup Volt Low Error . 660
Failure code [CA2249] Rail Press Very Low Error . 661
Failure code [CA2555] Grid Htr Relay Open Circuit Error . 662
Failure code [CA2556] Grid Htr Relay Short Circuit Error 664
Failure code [D110KB] Battery Relay Drive Short Circuit . 666
Failure code [D163KB] Flash Light Relay Short Circuit . 668
Failure code [D195KA] Step Light Relay Open Circuit . 670
Failure code [D195KB] Step Light Relay Short Circuit 672
Failure code [D19JKZ] Personal code relay abnormality . 674
Failure code [D862KA] GPS Antenna Open Circuit 677
Failure code [DA22KK] Pump Solenoid Power Low Error . 678
Failure code [DA25KP] 5V Sensor1 Power Abnormality 680
Failure code [DA29KQ] Model Selection Abnormality . 682
Failure code [DA2RMC] CAN Discon (Pump Con Detected) 684
Failure code [DA80MA] Auto. Lub. Abnormal . 688
Failure code [DAF8KB] Camera Power Supply Short Circuit . 690
Failure code [DAFGMC] GPS Module Error 692
Failure code [DAFRMC] CAN Discon (Monitor Detected) . 693
Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit . 698
Failure code [DGH2KB] Hyd Oil Sensor Short 700
Failure code [DHPAMA] F Pump Press Sensor Abnormality . 702
Failure code [DHPBMA] R Pump Press Sensor Abnormality . 704
Failure code [DV20KB] Travel alarm short circuit 706
Failure code [DW43KA] Travel Speed Sol Open Circuit . 708
Failure code [DW43KB] Travel Speed Sol Short Circuit 710
Failure code [DW45KA] Swing Brake Sol Open Circuit 712
Failure code [DW45KB] Swing Brake Sol Short Circuit . 714
Failure code [DW48KA] CO Cancel Sol Open Circuit 716
Failure code [DW48KB] CO Cancel Sol Short Circuit . 718
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol Open Circuit 720
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol Short Circuit . 722
Failure code [DW7BKA] Fan Reverse Sol Open Circuit 724
Failure code [DW7BKB] Fan Reverse Sol Short Circuit . 726
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit . 728
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 730
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit . 732
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit 733
Failure code [DXA0KA] TVC Sol Open Circuit 734
Failure code [DXA0KB] TVC Sol Short Circuit . 736
Failure code [DY20KA] Wiper Working Abnormality . 738
Failure code [DY20MA] Wiper Parking Abnormality . 742
Failure code [DY2CKA] Washer Drive Open Circuit . 744
Failure code [DY2CKB] Washer Drive Short Circuit 746
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit . 748
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit . 752
Failure code [DY2FMA] Upper Wiper Working Abnormality . 756
Failure code [DY2GKM] Wiper Select Abnormality 758
Troubleshooting of electrical system (E-mode) . 762
E-1 Engine does not start (Engine does not crank) . 762
E-2 Preheater does not operate 767
E-3 When starting switch is turned to ON position, machine monitor displays nothing . 771
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up . 774
E-5 Precaution item lights up while engine is running . 776
E-6 Emergency stop item lights up while engine is running . 778
E-7 Engine coolant temperature gauge does not indicate properly . 779
E-8 Fuel gauge does not indicate properly . 780
E-9 Hydraulic oil temperature gauge does not indicate properly 782
E-10 Content of display on machine monitor is different from that of actual machine . 784
E-11 Some areas of machine monitor screen are not displayed . 784
E-12 Function switch does not operate . 784
E-13 Automatic warm-up system does not operate (in cold season) . 785
E-14 Auto-decelerator does not operate properly . 786
E-15 Working mode does not change . 787
E-16 Travel speed does not change . 788
E-17 Alarm buzzer cannot be canceled 789
E-18 When starting switch is turned OFF, service meter is not displayed . 789
E-19 Service mode cannot be selected 789
E-20 Any of work equipment, swing and travel does not work or cannot be locked 790
E-21 Machine push-up function does not work or cannot be canceled . 792
E-22 Boom shockless function does not operate normally 794
E-23 Swing brake does not operate normally 796
E-24 Windshield wiper and window washer do not operate 798
E-25 Travel alarm does not sound or does not stop sounding 801
E-26 BOOM RAISE indicator is not displayed properly with monitoring function 802
E-27 BOOM LOWER indicator is not displayed properly with monitoring function 804
E-28 ARM IN indicator is not displayed properly with monitoring function 806
E-29 ARM DUMP indicator is not displayed properly with monitoring function 808
E-30 BUCKET CURL indicator is not displayed properly with monitoring function . 810
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function . 812
E-32 Swing indicator is not displayed properly with monitoring function . 814
E-33 Travel indicator is not displayed properly with monitoring function 816
E-34 “Service” is not displayed normally by monitoring function . 818
E-35 Electric grease gun does not operate . 820
E-36 KOMTRAX system does not operate normally . 821
E-37 Bottom dump does not operate properly 822
E-38 Horn does not sound or does not stop sounding 825
E-39 Step light does not light up or go off . 828
Troubleshooting of hydraulic and mechanical system (H-mode) . 832
Before troubleshooting for hydraulic and mechanical systems . 832
Information in troubleshooting table (H-mode) . 837
H-1 All of work equipment, travel and swing work slow or lack power . 838
H-2 Engine speed lowers significantly or engine stalls 840
H-3 Any of work equipment, swing and travel does not work . 842
H-4 Unusual noise is heard from around hydraulic pump . 844
H-5 Auto-decelerator is not canceled 845
H-6 Speed or power of boom is low . 846
H-7 Speed or power of arm is low 848
H-8 Speed or power of bucket is low . 849
H-9 Boom does not move 850
H-10 Arm does not move 850
H-11 Bucket does not move . 851
H-12 Bottom dump does not move 851
H-13 Hydraulic drift of work equipment is large . 852
H-14 Time lag of work equipment is large 853
H-15 One-touch power maximizing function does not work or is not canceled . 854
H-16 Machine push-up function does not work or is not canceled 854
H-17 Boom/bucket speed is low at combined operation of arm and boom or bucket . 854
H-18 Speed of boom, arm, swing and travel is low at combined operation of bucket and boom, arm, swing and travel 855
H-19 Swing speed is low at combined operation of arm and swing 855
H-20 Machine deviates during travel . 856
H-21 Machine deviates significantly at start 859
H-22 Machine deviates significantly during combined operation . 860
H-23 Travel speed or travel power is low 861
H-24 One of tracks does not run (on 1 side alone) . 862
H-25 Travel speed does not change . 863
H-26 Upper structure does not swing . 864
H-27 Swing speed is low or acceleration is poor . 865
H-28 Upper structure overruns excessively when it stops swinging 866
H-29 Shock is large when upper structure stops swinging . 867
H-30 Large unusual noise is heard when upper structure stops swinging . 868
H-31 Hydraulic drift of swing is large 869
Troubleshooting of engine (S-mode) 870
Method of using troubleshooting chart . 870
S-1 Startability is poor 874
S-2 Engine does not start . 875
S-3 Engine does not pick up smoothly 878
S-4 Engine stops during operation . 879
S-5 Engine runs rough or is unstable 880
S-6 Engine lacks power 882
S-7 Exhaust smoke is black (incomplete combustion) 884
S-8 Oil consumption is excessive (or exhaust smoke is blue) . 885
S-9 Oil becomes contaminated early 886
S-10 Fuel consumption is excessive 887
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) . 888
S-12 Oil pressure drops . 889
S-13 Oil level rises (coolant or fuel in oil) . 890
S-14 Coolant temperature rises too high (overheating) . 891
S-15 Unusual noise is made 892
S-16 Vibration is excessive . 893
50 Disassembly and assembly . 895
Contents 896
General information on disassembly and assembly . 898
How to read this manual . 898
Coating materials list 900
Special tools list 904
Sketches of special tools . 911
Engine and cooling system . 919
Removal and installation of fuel supply pump assembly . 919
Removal and installation of fuel injector assembly 925
Removal and installation of cylinder head assembly 928
Removal and installation of radiator assembly . 944
Removal and installation of hydraulic oil cooler assembly . 946
Removal and installation of aftercooler assembly 948
Removal and installation of engine front seal . 950
Removal and installation of engine rear seal 954
Removal and installation of engine, PTO and hydraulic pump assembly . 959
Removal and installation of cooling fan motor assembly 966
Removal and installation of fuel tank assembly 970
Power train . 971
Removal and installation of PTO assembly 971
Disassembly and assembly of PTO assembly 973
Disassembly and assembly of final drive assembly 976
Removal and installation of swing motor and swing machinery assembly 999
Disassembly and assembly of swing machinery assembly 1001
Removal and installation of swing circle assembly .1016
Undercarriage and frame .1017
Separation and connection of track shoe assembly 1017
Disassembly and assembly of one link in field .1021
Removal and installation of idler assembly 1025
Disassembly and assembly of idler assembly 1027
Removal and installation of idler cushion assembly 1034
Disassembly and assembly of idler cushion assembly 1037
Removal and installation of track roller assembly .1041
Disassembly and assembly of track roller assembly .1043
Removal and installation of carrier roller assembly .1049
Disassembly and assembly of carrier roller assembly .1051
Removal and installation of revolving frame assembly 1057
Removal and installation of counterweight assembly 1059
Removal and installation of counterweight remover assembly 1061
Hydraulic system 1063
Removal and installation of center swivel joint assembly 1063
Disassembly and assembly of center swivel joint assembly 1064
Removal and installation of hydraulic tank assembly .1066
Removal and installation of hydraulic pump assembly .1068
Removal and installation of control valve assembly 1072
Disassembly and assembly of control valve assembly 1074
Removal and installation of swing motor assembly 1076
Disassembly and assembly of work equipment PPC valve assembly .1077
Disassembly and assembly of travel PPC valve assembly .1079
Disassembly and assembly of grease gun assembly .1081
Work equipment 1082
Removal and installation of bucket cylinder assembly 1082
Removal and installation of arm cylinder assembly .1086
Removal and installation of boom cylinder assembly 1090
Removal and installation of bottom dump cylinder assembly .1094
Removal and installation of bucket assembly .1096
Removal and installation of arm assembly 1100
Removal and installation of boom assembly .1103
Removal and installation of work equipment assembly .1107
Disassembly and assembly of work equipment cylinder assembly 1111
Cab and its attachments .1117
Removal and installation of operator’s cab assembly .1117
Removal and installation of operator’s cab glass (adhered window glass) .1121
Removal and installation of front window assembly .1131
Removal and installation of air conditioner unit assembly .1138
Electrical system .1142
Removal and installation of air conditioner compressor assembly .1142
Removal and installation of air conditioner condenser assembly 1145
Removal and installation of engine controller assembly 1147
Removal and installation of pump controller assembly 1149
Removal and installation of KOMTRAX terminal assembly .1151
Removal and installation of machine monitor assembly 1152
60 Maintenance standard .1155
Contents 1156
Engine and cooling system .1157
Engine mount 1157
PTO .1159
Cooling system 1160
Power train .1161
Swing circle 1161
Swing machinery .1162
Final drive .1164
Sprocket 1166
Undercarriage and frame .1170
Track frame and idler cushion .1170
Idler .1172
Track roller 1176
Carrier roller 1179
Track shoe 1182
Hydraulic system 1192
Hydraulic pump 1192
Control valve .1202
Swing motor .1208
Travel motor 1209
PPC valve .1212
Boom drift prevention valve .1219
Regeneration valve (boom, arm) 1220
Center swivel joint .1221
Work equipment 1222
Work equipment 1222
Work equipment dimension 1226
Work equipment cylinder .1232
80 Appendix .1237
Table of contents .1238
Air conditioner .1239
Precautions for refrigerant .1239
Air conditioner component .1240
Configuration and function of refrigeration cycle .1242
Outline of refrigeration cycle 1243
Air conditioner unit 1246
Air conditioner controller 1251
Compressor 1252
Condenser .1253
Receiver drier 1254
Procedure for testing and troubleshooting .1256
Circuit diagram and arrangement of connector pins .1258
System diagram 1260
Detail of air conditioner unit 1262
Parts and connectors layout .1264
Testing air leakage (duct) 1267
Testing with self-diagnosis function 1268
Testing temperature control .1271
Testing vent (mode) changeover 1273
Testing FRESH/RECIRC air changeover .1276
Testing inner sensor 1278
Testing evaporator temperature sensor .1279
Testing sunlight sensor .1281
Testing (dual) pressure switch for refrigerant 1282
Testing relays 1283
Troubleshooting chart 1 .1284
Troubleshooting chart 2 .1286
Information in troubleshooting table 1288
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) 1290
Troubleshooting for compressor and refrigerant system (Air is not cooled) .1295
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1299
Troubleshooting for temperature control .1303
Troubleshooting for vent (mode) changeover 1306
Troubleshooting for FRESH/RECIRC air changeover .1308
Troubleshooting for temperature sensor system .1310
Troubleshooting with gauge pressure .1311
Connection of service tool 1314
Precautions for disconnecting and connecting air conditioner piping .1316
Handling of compressor oil 1318
90 Diagrams and drawings 1321
Contents 1322
Hydraulic circuit diagram .1323
Symbols used in hydraulic circuit diagrams 1323
Hydraulic circuit diagram .1327
Electrical circuit diagram 1331
Symbols used in electric circuit diagrams .1331
Electrical circuit diagram 1335
Air conditioner electrical circuit diagram 1347

DESCRIPTION:

Komatsu Excavator PC600-8R1,PC600LC-8R1,PC700LC-8R Shop Manual –  PDF DOWNLOAD

• SERIAL NUMBERS 70001 and up

G.B 27/12/24