Komatsu HYDRAULIC EXCAVATOR PC500LC-8R Shop Manual SEN06614-03 PDF

Description

Komatsu HYDRAULIC EXCAVATOR PC500LC-8R Shop Manual SEN06614-03 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC EXCAVATOR PC500LC-8R Shop Manual SEN06614-03 – PDF DOWNLOAD

Language : English
Pages :972
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC500LC-8R Shop Manual SEN06614-03 – PDF DOWNLOAD

SERIAL NUMBERS 75979 and up

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC500LC-8R Shop Manual SEN06614-03 – PDF DOWNLOAD

SERIAL NUMBERS 75979 and up

Cover 1
00 Index and foreword 3
Table of contents 4
Foreword and general information 11
Safety notice 11
How to read the shop manual 16
Explanation of terms for maintenance standard 18
Handling of electric equipment and hydraulic component 20
Handling of connectors newly used for engines 29
How to read electric wire code 32
Precautions when carrying out operation 35
Method of disassembling and connecting push-pull type coupler 38
Standard tightening torque table 41
Conversion table 45
01 Specification 51
Specification and technical data 53
Specification dimension drawings 53
Specifications 55
Weight table 58
Table of fuel, coolant and lubricants 60
10 Structure, function and maintenance standard 63
Engine and cooling system 65
Engine related parts 65
Radiator, oil cooler and aftercooler 66
Power train 67
Power train 67
Swing circle 68
Swing machinery 70
Final drive 72
Sprocket 76
Undercarriage and frame 79
Track frame and idler cushion 79
Track shoe 80
Triple-grouser shoe 82
Idler 84
Carrier roller 86
Track roller 87
Hydraulic system 88
Hydraulic equipment layout drawing 88
Hydraulic tank and filter 90
Hydraulic pump 92
Control valve116
CLSS128
Functions and operation by valve132
Merge-divider valve147
Attachment circuit selector valve172
Holding valve174
Valve control179
PPC valve180
Solenoid valve196
PPC accumulator198
Return oil filter199
Center swivel joint200
Travel motor201
Swing motor217
Hydraulic cylinder226
Work equipment228
Work equipment228
Dimensions of components230
Cab and its attachments234
Air conditioner piping234
Electrical system235
Engine control235
Electronic control system245
Monitor system270
Sensors297
KOMTRAX system300
20 Standard value table303
Standard service value table305
Standard value table for engine related parts305
Standard value table for chassis related parts306
30 Testing and adjusting317
Related information on testing and adjusting319
Tools for testing, adjusting and troubleshooting319
Sketches of special tools323
Engine and cooling system324
Measuring engine speed324
Measuring air boost pressure325
Measuring exhaust gas temperature326
Measuring exhaust gas color327
Adjusting valve clearance328
Measuring compression pressure330
Measuring blow-by pressure332
Testing engine oil pressure333
Handling fuel system parts334
Releasing residual pressure from fuel system334
Measuring fuel pressure335
Handling during cylinder cut-out operation336
Handling during no injection cranking operation336
Measuring fuel return rate and leakage337
Bleeding air from fuel circuit339
Checking fuel circuit for leakage343
Checking and adjusting fan belt and alternator belt344
Checking and adjusting air conditioner compressor belt tension345
Power train346
Testing swing circle bearing clearance346
Undercarriage and frame347
Testing and adjusting track shoe tension347
Hydraulic system348
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits348
Measuring control circuit basic pressure352
Checking and adjusting pump PC control circuit oil pressure353
Checking and adjusting pump LS control circuit oil pressure356
Measuring solenoid valve output pressure361
Measuring PPC valve output pressure364
Adjusting play of work equipment and swing PPC valves365
Inspecting locations of hydraulic drift of work equipment366
Releasing residual pressure from hydraulic circuit368
Measuring oil leakage amount369
Bleeding air from various parts372
Electrical system376
Special functions of machine monitor376
Handling voltage circuit of engine controller429
Preparation work for troubleshooting of electrical system430
Procedure for testing diodes435
Pm Clinic436
Pm Clinic service436
Undercarriage troubleshooting report442
40 Troubleshooting443
General Information on troubleshooting448
Points to remember when troubleshooting448
Sequence of events in troubleshooting449
Check before troubleshooting450
Classification and troubleshooting steps451
Information in troubleshooting table452
Connection table for connector pin numbers457
T- branch box and T- branch adapter table493
Failure code table and fuse locations496
Failure codes table496
Fuse locations498
Troubleshooting by failure code (Display of code)500
Failure code [AA10NX] Air cleaner Clogging500
Failure code [AB00KE] Charge Voltage Low502
Failure code [B@BAZG] Eng Oil Press Low504
Failure code [B@BAZK] Eng Oil Level Low507
Failure code [B@BCNS] Eng Water Overheat508
Failure code [B@BCZK] Eng Water Level Low510
Failure code [B@HANS] Hydr Oil Overheat512
Failure code [CA111] EMC Critical Internal Failure513
Failure code [CA115] Eng Ne and Bkup Speed Sens Error513
Failure code [CA122] Chg Air Press Sensor High Error514
Failure code [CA123] Chg Air Press Sensor Low Error516
Failure code [CA131] Throttle Sensor High Error518
Failure code [CA132] Throttle Sensor Low Error520
Failure code [CA135] Eng Oil Press Sensor High Error522
Failure code [CA141] Eng Oil Press Sensor Low Error525
Failure code [CA144] Coolant Temp Sens High Error526
Failure code [CA145] Coolant Temp Sens Low Error528
Failure code [CA153] Chg Air Temp Sensor High Error530
Failure code [CA154] Chg Air Temp Sensor Low Error532
Failure code [CA187] Sens Supply 2 Volt Low Error534
Failure code [CA221] Ambient Press Sens High Error536
Failure code [CA222] Ambient Press Sens Low Error538
Failure code [CA227] Sens Supply 2 Volt High Error540
Failure code [CA234] Eng Overspeed541
Failure code [CA238] Ne Speed Sens Supply Volt Error543
Failure code [CA263] Fuel Temp Sensor High Error544
Failure code [CA265] Fuel Temp Sensor Low Error546
Failure code [CA271] IMV/PCV1 Short Error547
Failure code [CA272] IMV/PCV1 Open Error548
Failure code [CA273] PCV2 Short Error550
Failure code [CA274] PCV2 Open Error552
Failure code [CA322] Inj #1 Open/Short Error554
Failure code [CA323] Inj #5 Open/Short Error556
Failure code [CA324] Inj #3 Open/Short Error558
Failure code [CA325] Inj #6 Open/Short Error560
Failure code [CA331] Inj #2 Open/Short Error562
Failure code [CA332] Inj #4 Open/Short Error564
Failure code [CA342] Calibration Code Incompatibility566
Failure code [CA351] Injectors Drive Circuit Error568
Failure code [CA352] Sens Supply 1 Volt Low Error570
Failure code [CA386] Sens Supply 1 Volt High Error572
Failure code [CA441] Battery Voltage Low Error574
Failure code [CA442] Battery Voltage High Error576
Failure code [CA449] Rail Press Very High Error578
Failure code [CA451] Rail Press Sensor High Error582
Failure code [CA452] Rail Press Sensor Low Error584
Failure code [CA553] Rail Press High Error586
Failure code [CA554] Rail Press Sensor In Range Error587
Failure code [CA559] Rail Press Low Error588
Failure code [CA689] Eng Ne Speed Sensor Error590
Failure code [CA731] Eng Bkup Speed Sens Phase Error592
Failure code [CA757] All Persistent Data Lost Error594
Failure code [CA778] Eng Bkup Speed Sensor Error596
Failure code [CA1633] KOMNET Datalink Timeout Error598
Failure code [CA2185] Throt Sens Sup Volt High Error600
Failure code [CA2186] Throt Sens Sup Volt Low Error601
Failure code [CA2249] Rail Press Very Low Error602
Failure code [CA2555] Grid Htr Relay Volt High Error604
Failure code [CA2556] Grid Htr Relay Volt Low Error606
Failure code [D110KB] Battery Relay Drive S/C608
Failure code [D196KA] Service Return Relay Disc610
Failure code [D196KB] Service Return Relay S/C612
Failure code [DA25KP] 5V sensor power supply output 1 abnormality614
Failure code [DA2SKQ] Model Selection Abnormality618
Failure code [DA2RMC] CAN discon (Pump con detected)620
Failure code [DAFRMC] CAN discon (Monitor detected)622
Failure code [DHPAMA] F Pump Press Sensor Abnormality624
Failure code [DHPBMA] R Pump Press Sensor Abnormality626
Failure code [DHS3MA] Arm Curl PPC Sen Abnormality628
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality630
Failure code [DW43KA] Travel Speed Sol Disc632
Failure code [DW43KB] Travel Speed Sol S/C634
Failure code [DW45KA] Swing Brake Sol Disc636
Failure code [DW45KB] Swing Brake Sol S/C640
Failure code [DW91KA] Travel Junction Sol Disc642
Failure code [DW91KB] Travel Junction Sol S/C644
Failure code [DWA2KA] Attachment Sol Open Circuit646
Failure code [DWJ0KA] Merge-divider Sol Disc648
Failure code [DWJ0KB] Merge-divider Sol S/C650
Failure code [DWK0KA] 2-stage Relief Sol Disc652
Failure code [DWK0KB] 2-stage Relief Sol S/C654
Failure code [DXA0KA] PC-EPC Sol Disc656
Failure code [DXA0KB] PC-EPC Sol S/C658
Failure code [DXE0KA] LS-EPC Sol Disc660
Failure code [DXE0KB] LS-EPC Sol S/C662
Failure code [DXE4KA] Service Current EPC Disc664
Failure code [DXE4KB] Service Current EPC S/C665
Failure code [DY20KA] Wiper Working Abnormality666
Failure code [DY20MA] Wiper Parking Abnormality668
Failure code [DY2CKB] Washer Drive Short670
Failure code [DY2DKB] Wiper Drive (For) Short672
Failure code [DY2EKB] Wiper Drive (Rev) Short674
Troubleshooting of electrical system (E-mode)676
Before carrying out troubleshooting of electrical system676
Information contained in troubleshooting table678
E-1 Engine does not start679
E-2 Auto-decelerator does not operate682
E-3 Automatic warming-up system does not operate684
E-4 Preheater does not operate686
E-5 All work equipment, swing, and travel mechanism do not move688
E-6 Power maximizing function does not operate690
E-7 Machine monitor does not display at all692
E-8 Machine monitor does not display some items694
E-9 Contents of display by machine monitor are different from applicable machine694
E-10 Fuel level monitor was lighted in red while engine running695
E-11 Engine coolant temperature gauge does not indicate normally696
E-12 Hydraulic oil temperature gauge does not indicate normally698
E-13 Fuel level gauge does not indicate normally699
E-14 Swing lock monitor does not indicate normally700
E-15 When monitor switch is operated, monitor displays nothing702
E-16 Windshield wiper and window washer do not operate704
E-17 Machine push-up function does not operate normally708
E-18 Monitoring function fails to display “boom raise” normally710
E-19 Monitoring function fails to display “boom lower” normally712
E-20 Monitoring function fails to display “arm IN” normally714
E-21 Monitoring function fails to display “arm OUT” normally716
E-22 Monitoring function fails to display “bucket CURL” normally718
E-23 Monitoring function fails to display “bucket DUMP” normally720
E-24 Monitoring function fails to display “swing” normally722
E-25 Monitoring function fails to display “travel” normally724
E-26 Monitoring function fails to display “travel differential pressure” normally726
E-27 Monitoring function fails to display “service” normally728
E-28 KOMTRAX system does not operate normally730
E-29 Air conditioner does not operate732
E-30 Travel alarm does not sound or does not stop sounding734
E-31 Horn does not sound736
E-32 Electric priming pump does not operate or does not stop automatically738
Troubleshooting of hydraulic and mechanical system (H-mode)740
System chart for hydraulic and mechanical system740
Information contained in troubleshooting table742
H-1 All work equipment lack power, or travel and swing speeds are slow744
H-2 Engine speed sharply drops or engine stalls746
H-3 No work equipment, swing or travel move747
H-4 Abnormal noise is heard from around hydraulic pump747
H-5 Auto-decelerator does not work748
H-6 Fine control mode does not function or responds slow748
H-7 Boom moves slowly or lacks power749
H-8 Arm moves slowly or lacks power750
H-9 Bucket moves slowly or lacks power751
H-10 Work equipment does not move in its single operation751
H-11 Work equipment has a bit too fast hydraulic drift752
H-12 Work equipment has big time lag754
H-13 Other work equipment moves when relieving single circuit754
H-14 Power max switch does not operate754
H-15 Machine push-up function does not operate755
H-16 In compound operation of work equipment, speed of part loaded more is low756
H-17 When machine swings and raises boom simultaneously, boom rising speed is low756
H-18 When machine swings and travels simultaneously, travel speed lowers largely756
H-19 Machine deviates during travel757
H-20 Travel speed is low758
H-21 Machine is not steered well or steering power is low759
H-22 Travel speed does not change or travel speed is low or high760
H-23 Travel system does not move (only one side)761
H-24 Upper structure does not swing762
H-25 Swing acceleration or swing speed is low764
H-26 Upper structure overruns remarkably when it stops swinging766
H-27 Large shock is made when upper structure stops swinging767
H-28 Large sound is made when upper structure stops swinging767
H-29 Hydraulic drift of swing is large768
H-30 Attachment circuit is not changed769
H-31 Oil flow in attachment circuit cannot be controlled769
Troubleshooting of engine (S-mode)771
Method of using troubleshooting chart771
S-1 Starting performance is poor774
S-2 Engine does not start775
S-3 Engine does not pick up smoothly778
S-4 Engine stops during operations779
S-5 Engine does not rotate smoothly780
S-6 Engine lacks output (or lacks power)781
S-7 Exhaust smoke is black (incomplete combustion)782
S-8 Oil consumption is excessive (or exhaust smoke is blue)783
S-9 Oil becomes contaminated quickly784
S-10 Fuel consumption is excessive785
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)786
S-12 Oil pressure drops787
S-13 Oil level rises (Entry of coolant or fuel)788
S-14 Coolant temperature becomes too high (overheating)789
S-15 Abnormal noise is made790
S-16 Vibration is excessive791
S-17 Air cannot be bled from fuel circuit792
50 Disassembly and assembly793
Related information on disassembly and assembly796
How to read this manual796
Coating materials list798
Special tools list801
Sketches of special tools804
Engine and cooling system808
Removal and installation of fuel supply pump assembly808
Removal and installation of fuel injector assembly812
Removal and installation of engine front seal818
Removal and installation of engine rear seal819
Removal and installation of cylinder head assembly822
Removal and installation of radiator assembly831
Removal and installation of hydraulic oil cooler assembly833
Removal and installation of aftercooler assembly835
Removal and installation of engine and hydraulic oil pump assembly836
Power train843
Removal and installation of travel motor and final drive assembly843
Disassembly and assembly of final drive844
Removal and installation of swing motor and swing machinery assembly852
Disassembly and assembly of swing motor and swing machinery assembly853
Removal and installation of swing circle assembly860
Undercarriage and frame861
Separation and connection of track shoe assembly861
Removal and installation of sprocket863
Removal and installation of idler and idler cushion assembly864
Disassembly and assembly of idler865
Disassembly and assembly of idler cushion868
Disassembly and assembly of track roller870
Disassembly and assembly of carrier roller871
Removal and installation of revolving frame assembly873
Removal and installation of counterweight assembly876
Hydraulic system879
Removal and installation of center swivel joint assembly879
Disassembly and assembly of center swivel joint assembly881
Removal and installation of hydraulic tank assembly882
Removal and installation of control valve assembly884
Disassembly and assembly of control valve assembly887
Removal and installation of hydraulic pump assembly889
Removal and installation of oil seal in hydraulic pump input shaft892
Disassembly and assembly of work equipment PPC valve assembly893
Disassembly and assembly of travel PPC valve assembly894
Disassembly and assembly of hydraulic cylinder assembly895
Work equipment901
Removal and installation of work equipment assembly901
Cab and its attachments904
Removal and installation of operator cab assembly904
Removal and installation of operator cab glass (stuck glass)907
Removal and installation of front window assembly917
Removal and installation of floor frame assembly924
Removal and installation of work equipment control lever assembly928
Electrical system941
Removal and installation of air conditioner unit assembly941
Removal and installation of KOMTRAX communication modem assembly944
Removal and installation of monitor assembly945
Removal and installation of pump controller assembly947
Removal and installation of engine controller949
90 Diagrams and drawings951
Hydraulic diagrams and drawings953
Hydraulic circuit diagram953
Electrical diagrams and drawings955
Electrical circuit diagram955
Connector arrangement diagram965
Index967

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24