Komatsu HYDRAULIC EXCAVATOR PC600 -8E0 PC600LC-8E0 PC650 -8E0 PC650LC-8E0 PC700LC-8E0 Shop Manual SEN05377-15

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Komatsu HYDRAULIC EXCAVATOR PC600 -8E0 PC600LC-8E0 PC650 -8E0 PC650LC-8E0 PC700LC-8E0 Shop Manual SEN05377-15 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC600 -8E0 PC600LC-8E0 PC650 -8E0 PC650LC-8E0 PC700LC-8E0 Shop Manual SEN05377-15 – PDF DOWNLOAD

Language : English
Pages :1410
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC600 -8E0 PC600LC-8E0 PC650 -8E0 PC650LC-8E0 PC700LC-8E0 Shop Manual SEN05377-15 – PDF DOWNLOAD

SERIAL NUMBERS 65001 and up

1. General precautions 

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC600 -8E0 PC600LC-8E0 PC650 -8E0 PC650LC-8E0 PC700LC-8E0 Shop Manual SEN05377-15 – PDF DOWNLOAD

SERIAL NUMBERS 65001 and up

Cover 1
00 Index and foreword 3
Table of Contents 4
Foreword and general information 14
Safety notice 14
How to read the shop manual 19
Explanation of terms for maintenance standard 21
Handling of hydraulic components 23
Method of disconnecting and connecting push-pull type coupler 25
Handling of electric equipment 28
How to read electric wire code 38
Precautions when performing work 41
Standard tightening torque table 44
List of abbreviation 48
Conversion table 52
01 Specification 57
Contents 58
Specifications 60
Specifications drawing 60
Working range drawings 62
Specifications 64
Table of weight 74
Table of fuel, coolant and lubricants 82
10 Structure and function 85
Contents 86
Engine and cooling system 87
Engine related parts 87
PTO 88
Cooling system 89
Power train system 90
Power train 90
Swing circle 92
Swing machinery 94
Final drive 96
Undercarriage and frame 98
Track frame and idler cushion 98
Hydraulic system 100
Hydraulic component layout 100
Valve control 102
Hydraulic tank and filter 104
Hydraulic pump (piston pump) 106
Cooling fan pump 134
Cooling fan motor 142
Control valve 148
Swing motor 164
Travel motor 172
PPC valve 193
Solenoid valve 201
PPC shuttle valve 208
Boom drift prevention valve 209
Boom LOWER regeneration valve 213
Arm regeneration valve 216
Quick return valve 219
Line oil filter 222
Center swivel joint 223
Accumulator 224
Electrical system 225
Engine control 225
Electrical control system 235
Monitor system 265
KOMTRAX system 291
Sensors 293
20 Standard value table 297
Contents 298
Standard value table 299
Standard value table for engine 299
Standard value table for machine 300
30 Testing and adjusting 323
Contents 324
Tool for testing, adjusting and troubleshooting 325
Tools for testing, adjusting, and troubleshooting 325
Engine and cooling system 329
Testing engine speed 329
Testing intake air pressure (boost pressure) 331
Testing exhaust gas temperature 332
Testing exhaust gas color 333
Testing and adjusting valve clearance 334
Testing compression pressure 335
Testing blowby pressure 337
Testing engine oil pressure 338
Testing EGR valve and bypass valve drive pressure 339
Handling fuel system parts 340
Releasing remaining pressure from fuel system 341
Testing fuel pressure 342
Cylinder cut-out test mode 343
No-injection cranking 344
Testing fuel return rate and leakage 345
Bleeding air from fuel circuit 348
Testing fuel circuit for leakage 350
Testing and adjusting alternator belt tension 351
Testing and adjusting air conditioner compressor belt tension 352
Undercarriage and frame 353
Testing swing circle bearing clearance 353
Checking and adjusting track tension 354
Hydraulic system 355
Testing and adjusting oil pressure in work equipment, swing and travel circuits 355
Testing and adjusting control circuit oil pressure 360
Testing and adjusting control oil pressure of piston pump 362
Testing servo piston movement 368
Testing PPC valve output pressure 370
Testing output pressure of solenoid valve and PPC shuttle valve 374
Adjusting play of work equipment and swing PPC vavles 380
Isolating the parts causing hydraulic drift in work equipment 381
Testing and adjusting travel deviation 383
Testing fan speed 385
Testing fan circuit oil pressure 386
Releasing remaining pressure from hydraulic circuit 387
Testing oil leakage 388
Bleeding air from each part 392
Electrical system 395
Special functions of machine monitor 395
Handling of voltage circuit of engine controller 439
Preparatory work for troubleshooting of electrical system 440
Inspection procedure of diode 445
Pm clinic 446
Pm Clinic service 446
UNDERCARRIAGE INSPECTION REPORT 460
40 Troubleshooting 463
Contents 464
General information on troubleshooting 470
Points to remember when troubleshooting 470
Sequence of events in troubleshooting 471
Checks before troubleshooting 472
Classification and procedures for troubleshooting 496
Failure codes table 499
Symptom and troubleshooting numbers 503
Information in troubleshooting table 506
Troubleshooting method for open circuit in wiring harness of pressure sensor system 508
Connector list and layout 510
Connection table for connector pin numbers 520
T- branch box and T- branch adapter table 556
Fuse locations 559
Troubleshooting by failure code 562
Failure code [989L00] Engine Controller Lock Caution 1 562
Failure code [989M00] Engine Controller Lock Caution 2 563
Failure code [989N00] Engine Controller Lock Caution 3 564
Failure code [AA10NX] Air Cleaner Clogging 565
Failure code [AB00KE] Charge Voltage Low 566
Failure code [B@BAZG] Eng Oil Press Low 568
Failure code [B@BAZK] Eng Oil Level Low 569
Failure code [B@BCNS] Eng Water Overheat 570
Failure code [B@BCZK] Eng Water Level Low 572
Failure code [B@HANS] Hyd Oil Overheat 574
Failure code [CA111] ECM Critical Internal Failure 576
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 578
Failure code [CA122] Chg Air Press Sensor High Error 580
Failure code [CA123] Chg Air Press Sensor Low Error 582
Failure code [CA131] Throttle Sensor High Error 584
Failure code [CA132] Throttle Sensor Low Error 586
Failure code [CA135] Eng Oil Press Sensor High Error 588
Failure code [CA141] Eng Oil Press Sensor Low Error 590
Failure code [CA144] Coolant Temp Sens High Error 592
Failure code [CA145] Coolant Temp Sens Low Error 594
Failure code [CA153] Chg Air Temp Sensor High Error 596
Failure code [CA154] Chg Air Temp Sensor Low Error 598
Failure code [CA187] Sens Supply 2 Volt Low Error 600
Failure code [CA221] Ambient Press Sens High Error 602
Failure code [CA222] Ambient Press Sens Low Error 604
Failure code [CA227] Sens Supply 2 Volt High Error 606
Failure code [CA234] Eng Overspeed 607
Failure code [CA238] Ne Speed Sens Supply Volt Error 608
Failure code [CA263] Fuel Temp Sensor High Error 610
Failure code [CA265] Fuel Temp Sensor Low Error 612
Failure code [CA271] IMV/PCV1 Short Error 614
Failure code [CA272] IMV/PCV1 Open Error 615
Failure code [CA273] PCV2 Short Error 616
Failure code [CA274] PCV2 Open Error 617
Failure code [CA322] Inj #1(L#1) Open/Short Error 618
Failure code [CA323] Inj #5 (L#5) Open/Short Error 620
Failure code [CA324] Inj #3(L#3) Open/Short Error 622
Failure code [CA325] Inj #6 (L#6) Open/Short Error 624
Failure code [CA331] Inj #2(L#2) Open/Short Error 626
Failure code [CA332] Inj #4 (L#4) Open/Short Error 628
Failure code [CA342] Calibration Code Incompatibility 630
Failure code [CA351] Injectors Drive Circuit Error 631
Failure code [CA352] Sens Supply 1 Volt Low Error 632
Failure code [CA386] Sens Supply 1 Volt High Error 634
Failure code [CA441] Battery Voltage Low Error 634
Failure code [CA442] Battery Voltage High Error 635
Failure code [CA449] Rail Press Very High Error 635
Failure code [CA451] Rail Press Sensor High Error 636
Failure code [CA452] Rail Press Sensor Low Error 638
Failure code [CA553] Rail Press High Error 640
Failure code [CA554] Rail Press Sensor In Range Error 640
Failure code [CA559] Supply Pump Press Low Error 1 641
Failure code [CA689] Eng Ne Speed Sensor Error 644
Failure code [CA731] Eng Bkup Speed Sens Phase Error 646
Failure code [CA757] All Continuous Data Lost Error 647
Failure code [CA778] Eng Bkup Speed Sensor Error 648
Failure code [CA1228] EGR Valve Servo Error 1 650
Failure code [CA1625] EGR Valve Servo Error 2 651
Failure code [CA1626] BP Valve Sol Current High Error 652
Failure code [CA1627] BP Valve Sol Current Low Error 654
Failure code [CA1628] Bypass Valve Servo Error 1 656
Failure code [CA1629] Bypass Valve Servo Error 2 657
Failure code [CA1631] BP Valve Pos Sens High Error 658
Failure code [CA1632] BP Valve Pos Sens Low Error 660
Failure code [CA1633] KOMNET Datalink Timeout Error 662
Failure code [CA2185] Throt Sens Sup Volt High Error 664
Failure code [CA2186] Throt Sens Sup Volt Low Error 666
Failure code [CA2249] Rail Press Very Low Error 667
Failure code [CA2271] EGR Valve Pos Sens High Error 668
Failure code [CA2272] EGR Valve Pos Sens Low Error 670
Failure code [CA2351] EGR Valve Sol Current High Error 672
Failure code [CA2352] EGR Valve Sol Current Low Error 674
Failure code [CA2555] Grid Htr Relay Open Circuit Error 676
Failure code [CA2556] Grid Htr Relay Short Circuit Error 678
Failure code [D110KB] Battery Relay Drive Short Circuit 680
Failure code [D163KB] Flash Light Relay Short Circuit 682
Failure code [D195KA] Step Light Relay Open Circuit 684
Failure code [D195KB] Step Light Relay Short Circuit 686
Failure code [D19JKZ] Personal code relay abnormality 688
Failure code [D862KA] GPS Antenna Open Circuit 690
Failure code [DA22KK] Pump Solenoid Power Low Error 692
Failure code [DA25KP] 5V Sensor1 Power Abnormality 694
Failure code [DA29KQ] Model Selection Abnormality 696
Failure code [DA2RMC] CAN Discon (Pump Con Detected) 698
Failure code [DA80MA] Auto Lub Abnormal 702
Failure code [DAF8KB] Camera Power Supply Short Circuit 704
Failure code [DAFGMC] GPS Module Error 706
Failure code [DAFRMC] CAN Discon (Monitor Detected) 707
Failure code [DGE5KB] Ambi Temp Sensor Short Circuit 712
Failure code [DGH2KB] Hyd Oil Sensor Short 714
Failure code [DHPAMA] F Pump Press Sensor Abnormality 716
Failure code [DHPBMA] R Pump Press Sensor Abnormality 718
Failure code [DV20KB] Travel alarm short circuit 720
Failure code [DW43KA] Travel Speed Sol Open Circuit 722
Failure code [DW43KB] Travel Speed Sol Short Circuit 724
Failure code [DW45KA] Swing Brake Sol Open Circuit 726
Failure code [DW45KB] Swing Brake Sol Short Circuit 728
Failure code [DW48KA] CO Cancel Sol Open Circuit 730
Failure code [DW48KB] CO Cancel Sol Short Circuit 732
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol Open Circuit 734
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol Short Circuit 736
Failure code [DW7BKA] Fan Reverse Sol Open Circuit 738
Failure code [DW7BKB] Fan Reverse Sol Short Circuit 740
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 742
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 744
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit 746
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit 747
Failure code [DXA0KA] TVC Sol Open Circuit 748
Failure code [DXA0KB] TVC Sol Short Circuit 750
Failure code [DY20KA] Wiper Working Abnormality 752
Failure code [DY20MA] Wiper Parking Abnormality 756
Failure code [DY2CKA] Washer Drive Open Circuit 758
Failure code [DY2CKB] Washer Drive Short Circuit 760
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 762
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 766
Failure code [DY2FMA] Upper Wiper Working Abnormality 770
Failure code [DY2GKM] Wiper Select Abnormality 772
Troubleshooting of electrical system (E-mode) 776
E-1 Engine does not start (Engine does not crank) 776
E-2 Preheater does not operate 781
E-3 When starting switch is turned to ON position, machine monitor displays nothing 785
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up 788
E-5 Precaution item lights up while engine is running 790
E-6 Emergency stop item lights up while engine is running 792
E-7 Engine coolant temperature gauge does not indicate properly 793
E-8 Fuel gauge does not indicate properly 794
E-9 Hydraulic oil temperature gauge does not indicate properly 796
E-10 Content of display on machine monitor is different from that of actual machine 798
E-11 Some areas of machine monitor screen are not displayed 798
E-12 Function switch does not operate 798
E-13 Automatic warm-up system does not operate (in cold season) 799
E-14 Auto-decelerator does not operate properly 800
E-15 Working mode does not change 801
E-16 Travel speed does not change 802
E-17 Alarm buzzer cannot be canceled 803
E-18 When starting switch is turned OFF, service meter is not displayed 803
E-19 Service mode cannot be selected 803
E-20 Any of work equipment, swing and travel does not work or cannot be locked 804
E-21 Machine push-up function does not work or cannot be canceled 806
E-22 Boom shockless function does not operate normally 808
E-23 Swing brake does not operate normally 810
E-24 Windshield wiper and window washer do not operate 812
E-25 Travel alarm does not sound or does not stop sounding 815
E-26 BOOM RAISE indicator is not displayed properly with monitoring function 816
E-27 BOOM LOWER indicator is not displayed properly with monitoring function 818
E-28 ARM IN indicator is not displayed properly with monitoring function 820
E-29 ARM DUMP indicator is not displayed properly with monitoring function 822
E-30 BUCKET CURL indicator is not displayed properly with monitoring function 824
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function 826
E-32 Swing indicator is not displayed properly with monitoring function 828
E-33 Travel indicator is not displayed properly with monitoring function 830
E-34 “Service” is not displayed normally by monitoring function 832
E-35 Electric grease gun does not operate 834
E-36 KOMTRAX system does not operate normally 835
E-37 Bottom dump does not operate properly 836
E-38 Horn does not sound or does not stop sounding 839
E-39 Step light does not light up or go off 842
Troubleshooting of hydraulic and mechanical system (H-mode) 846
Before troubleshooting for hydraulic and mechanical systems 846
Information in troubleshooting table (H-mode) 851
H-1 All of work equipment, travel and swing work slow or lack power 852
H-2 Engine speed lowers significantly or engine stalls 854
H-3 Any of work equipment, swing and travel does not work 856
H-4 Unusual noise is heard from around hydraulic pump 858
H-5 Auto-decelerator is not canceled 859
H-6 Speed or power of boom is low 860
H-7 Speed or power of arm is low 862
H-8 Speed or power of bucket is low 863
H-9 Boom does not move 864
H-10 Arm does not move 864
H-11 Bucket does not move 865
H-12 Bottom dump does not move 865
H-13 Hydraulic drift of work equipment is large 866
H-14 Time lag of work equipment is large 867
H-15 One-touch power maximizing function does not work or is not canceled 868
H-16 Machine push-up function does not work or is not canceled 868
H-17 Boom/bucket speed is low at combined operation of arm and boom or bucket 868
H-18 Speed of boom, arm, swing and travel is low at combined operation of bucket and boom, arm, swing and travel 869
H-19 Swing speed is low at combined operation of arm and swing 869
H-20 Machine deviates during travel 870
H-21 Machine deviates significantly at start 873
H-22 Machine deviates significantly during combined operation 874
H-23 Travel speed or travel power is low 875
H-24 One of tracks does not run (on one side alone) 876
H-25 Travel speed does not change 877
H-26 Upper structure does not swing 878
H-27 Swing speed is low or acceleration is poor 879
H-28 Upper structure overruns excessively when it stops swinging 880
H-29 Shock is large when upper structure stops swinging 881
H-30 Large unusual noise is heard when upper structure stops swinging 882
H-31 Hydraulic drift of swing is large 883
Troubleshooting of engine (S-mode) 884
Method of using troubleshooting chart 884
S-1 Startability is poor 888
S-2 Engine does not start 890
S-3 Engine does not pick up smoothly 894
S-4 Engine stops during operation 895
S-5 Engine runs rough or is unstable 896
S-6 Engine lacks power 898
S-7 Exhaust smoke is black (incomplete combustion) 900
S-8 Oil consumption is excessive (or exhaust smoke is blue) 902
S-9 Oil becomes contaminated early 903
S-10 Fuel consumption is excessive 904
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) 905
S-12 Oil pressure drops 906
S-13 Oil level rises (coolant or fuel in oil) 908
S-14 Coolant temperature rises too high (overheating) 910
S-15 Unusual noise is made 911
S-16 Vibration is excessive 912
50 Disassembly and assembly 913
Contents 914
General information on disassembly and assembly 916
How to read Disassembly and Assembly 916
Coating materials list 918
Special tools list 921
Sketches of special tools 928
Engine and cooling system 936
Removal and installation of fuel supply pump assembly 936
Removal and installation of fuel injector assembly 942
Removal and installation of cylinder head assembly 945
Removal and installation of radiator assembly 962
Removal and installation of hydraulic oil cooler assembly 964
Removal and installation of aftercooler assembly 966
Removal and installation of engine front seal 968
Removal and installation of engine rear seal 972
Removal and installation of engine, PTO and hydraulic pump assembly 977
Removal and installation of cooling fan motor assembly 985
Removal and installation of fuel tank assembly 989
Power train 990
Removal and installation of PTO assembly 990
Disassembly and assembly of PTO assembly 992
Disassembly and assembly of final drive assembly 995
Removal and installation of swing motor and swing machinery assembly1018
Disassembly and assembly of swing machinery assembly1020
Removal and installation of swing circle assembly1035
Undercarriage and frame1036
Separation and connection of track shoe assembly1036
Disassembly and assembly of one link in field1040
Removal and installation of idler assembly1044
Disassembly and assembly of idler assembly1046
Removal and installation of idler cushion assembly1053
Disassembly and assembly of idler cushion assembly1056
Removal and installation of track roller assembly1060
Disassembly and assembly of track roller assembly1062
Removal and installation of carrier roller assembly1068
Disassembly and assembly of carrier roller assembly1070
Removal and installation of revolving frame assembly1076
Removal and installation of counterweight assembly1078
Removal and installation of counterweight remover assembly1079
Hydraulic system1081
Removal and installation of center swivel joint assembly1081
Disassembly and assembly of center swivel joint assembly1082
Removal and installation of hydraulic tank assembly1084
Removal and installation of hydraulic pump assembly1086
Removal and installation of control valve assembly1089
Disassembly and assembly of control valve assembly1091
Removal and installation of swing motor assembly1093
Disassembly and assembly of work equipment PPC valve assembly1094
Disassembly and assembly of travel PPC valve assembly1096
Disassembly and assembly of grease gun assembly1098
Work equipment1099
Removal and installation of bucket cylinder assembly1099
Removal and installation of arm cylinder assembly1103
Removal and installation of boom cylinder assembly1107
Removal and installation of bottom dump cylinder assembly1111
Removal and installation of bucket assembly1113
Removal and installation of arm assembly1117
Removal and installation of boom assembly1120
Removal and installation of work equipment assembly1124
Removal and installation of anti- drop valve assembly for boom1128
Removal and installation of anti- drop valve assembly for arm1131
Disassembly and assembly anti- drop valve assembly1134
Disassembly and assembly of work equipment cylinder assembly1136
Cab and its attachments1142
Removal and installation of operator’s cab assembly1142
Removal and installation of operator’s cab glass (adhered window glass)1146
Removal and installation of front window assembly1156
Removal and installation of air conditioner unit assembly1163
Removal and installation of work equipment control lever assembly1167
Electrical system1181
Removal and installation of air conditioner compressor assembly1181
Removal and installation of air conditioner condenser assembly1184
Removal and installation of engine controller assembly1186
Removal and installation of pump controller assembly1188
Removal and installation of KOMTRAX terminal assembly1190
Removal and installation of machine monitor assembly1191
60 Maintenance standard1193
Contents1194
Engine and cooling system1195
Engine mount1195
PTO1197
Cooling system1198
Power train1199
Swing circle1199
Swing machinery1200
Final drive1202
Sprocket1204
Undercarriage and frame1208
Track frame and idler cushion1208
Idler1210
Track roller1214
Carrier roller1217
Track shoe1220
Hydraulic system1230
Hydraulic pump1230
Control valve1240
Swing motor1246
Travel motor1247
PPC valve1250
Boom drift prevention valve1257
Regeneration valve (boom, arm)1258
Center swivel joint1259
Work equipment1260
Work equipment1260
Work equipment dimension1264
Work equipment cylinder1270
80 Appendix1275
Table of contents1276
Air conditioner1277
Precautions for refrigerant1277
Air conditioner component1278
Configuration and function of refrigeration cycle1280
Outline of refrigeration cycle1281
Air conditioner unit1284
Air conditioner controller1289
Compressor1290
Condenser1291
Receiver drier1292
Procedure for testing and troubleshooting1294
Circuit diagram and arrangement of connector pins1296
System diagram1298
Detail of air conditioner unit1300
Parts and connectors layout1302
Testing air leakage (duct)1305
Testing with self-diagnosis function1306
Testing temperature control1309
Testing vent (mode) changeover1311
Testing FRESH/RECIRC air changeover1314
Testing inner sensor1316
Testing evaporator temperature sensor1317
Testing sunlight sensor1319
Testing (dual) pressure switch for refrigerant1320
Testing relays1321
Troubleshooting chart 11322
Troubleshooting chart 21324
Information in troubleshooting table1326
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)1328
Troubleshooting for compressor and refrigerant system (Air is not cooled)1333
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)1337
Troubleshooting for temperature control1341
Troubleshooting for vent (mode) changeover1344
Troubleshooting for FRESH/RECIRC air changeover1346
Troubleshooting for temperature sensor system1348
Troubleshooting with gauge pressure1349
Connection of service tool1352
Precautions for disconnecting and connecting air conditioner piping1354
Handling of compressor oil1356
90 Diagrams and drawings1359
Contents1360
Hydraulic circuit diagram1361
Symbols used in hydraulic circuit diagrams1361
Hydraulic circuit diagram1365
Electrical circuit diagram1373
Symbols used in electric circuit diagrams1373
Electrical circuit diagram1377
Air conditioner electrical circuit diagram1401
Index1403
A1403
B1403
C1403
D1403
E1403
F1404
H1405
I1406
K1406
L1406
M1406
N1406
O1406
P1406
Q1406
R1406
S1407
T1407
U1408
V1408
W1408

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S.M 26/12/24