Komatsu Hydraulic Excavator PC600 8PC600 LC-8 PC800 K50001 PC 800 LC-K Service Repair Manual – PDF Download

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Komatsu Hydraulic Excavator PC600 8PC600 LC-8 PC800 K50001 PC 800 LC-K Service Repair Manual Download

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Komatsu Hydraulic Excavator PC600 8PC600 LC-8 PC800 K50001 PC 800 LC-K Service Repair Manual Download

LANGUAGE:ENGLISH
PAGES:1914
DOWNLOADABLE:YES
FILE TYPE:PDF

KOMATSU HYDRAULIC EXCAVATOR PC600 8PC600 LC-8 PC800 K50001 PC 800 LC-K SERVICE REPAIR MANUAL – PDF DOWNLOAD:

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• Komatsu Hydraulic Excavator PC600 8PC600 LC-8 PC800 K50001 PC 800 LC-K Service Repair Manual Download
• 1. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information.
• 01. Specification This section explains the specifications of the machine.
• 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
• 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
• 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
• 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
• 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
• 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC600 8PC600 LC-8 PC800 K50001 PC 800 LC-K Service Repair Manual Download

00 Index and foreword....................................................................  3
	Organization list of the shop manual.................................................  4
	Table of contents....................................................................  6
00 Index and foreword.................................................................... 15
	Foreword and general information..................................................... 16
		Safety notice.................................................................... 16
		How to read the shop manual...................................................... 20
		Explanation of terms for maintenance standard.................................... 22
		Handling electric equipment and hydraulic component.............................. 24
		How to read electric wire code................................................... 32
		Method of disassembling and connecting push-pull type coupler.................... 35
		Standard tightening torque table................................................. 38
		Conversion table................................................................. 42
01 Specification......................................................................... 49
	Specification and technical data..................................................... 50
		Specification drawings........................................................... 50
		Working range drawings........................................................... 51
		Specifications................................................................... 52
		Weight table..................................................................... 58
		Table of fuel, coolant and lubricants............................................ 60
10 Structure, function and maintenance standard.......................................... 63
	Engine and cooling system............................................................ 64
		Parts related to engine.......................................................... 64
		PTO.............................................................................. 66
		Fan, control and PTO lubrication pump............................................ 68
		Radiator, oil cooler............................................................. 69
10 Structure, function and maintenance standard.......................................... 71
	Power train.......................................................................... 72
		Power train...................................................................... 72
		Final drive...................................................................... 75
		Sprocket......................................................................... 78
		Swing circle..................................................................... 80
		Swing machinery.................................................................. 82
10 Structure, function and maintenance standard.......................................... 85
	Undercarriage and frame.............................................................. 86
		Track frame, recoil spring....................................................... 86
		Idler............................................................................ 88
		Carrier roller................................................................... 90
		Track roller..................................................................... 91
		Track shoe....................................................................... 92
10 Structure, function and maintenance standard.......................................... 99
	Hydraulic system, Part 1.............................................................100
		Hydraulic piping drawing.........................................................100
		Hydraulic tank, hydraulic filter.................................................102
		Hydraulic pump (piston pump).....................................................104
		Line oil filter..................................................................132
		Cooling fan pump.................................................................134
		Cooling fan motor................................................................142
10 Structure, function and maintenance standard..........................................149
	Hydraulic system, Part 2.............................................................150
		Control valve....................................................................150
		Swing motor......................................................................169
		Swing brake......................................................................172
		Safety valve.....................................................................173
		Reverse prevention valve.........................................................175
		Center swivel joint..............................................................178
		Travel motor.....................................................................179
		Parking brake....................................................................184
		Brake valve......................................................................186
		Set pressures varying mechanism..................................................189
		Valve control....................................................................190
		Work equipment, swing PPC valve..................................................192
		Travel PPC valve.................................................................196
		Service PPC valve................................................................198
		PPC accumulator..................................................................199
		PPC shuttle valve................................................................200
		Solenoid valve...................................................................201
		Boom holding valve...............................................................206
		Boom LOWER regeneration valve....................................................210
		Hydraulic drift prevention valve.................................................214
		Hydraulic cylinder...............................................................220
10 Structure, function and maintenance standard..........................................223
	Work equipment.......................................................................224
		Work equipment...................................................................224
		Dimensions of work equpment......................................................226
10 Structure, function and maintenance standard..........................................231
	Cab and its attachments..............................................................232
		Air conditioner piping...........................................................232
10 Structure, function and maintenance standard..........................................235
	Engine control.......................................................................236
	Machine control system diagram.......................................................241
	Monitor system.......................................................................265
	Sensors..............................................................................280
20 Standard value table..................................................................285
	Standard service value table.........................................................286
		Standard value table for engine..................................................286
		Standard value table for chassis.................................................287
30 Testing and adjusting.................................................................297
	Testing and adjusting, Part 1........................................................300
		Tools for testing, adjusting and troubleshooting.................................300
		Measuring engine speed...........................................................302
		Measuring intake air pressure (boost pressure)...................................303
		Measuring exhaust gas temperature................................................304
		Measuring exhaust gas color......................................................305
		Adjusting valve clearance........................................................306
		Measuring compression pressure...................................................307
		Measuring blow-by pressure.......................................................309
		Measuring engine oil pressure....................................................309
		Handling equipment in fuel circuit...............................................310
		Releasing remaining pressure in fuel system......................................310
		Measuring fuel pressure..........................................................311
		Reduced cylinder mode operation..................................................312
		No-injection cranking............................................................312
		Testing leakage from pressure limiter and return rate from injector..............313
		Bleeding air from fuel circuit...................................................315
		Testing fuel system for leakage..................................................316
		Adjusting speed sensor...........................................................317
		Testing and adjusting alternator belt tension....................................317
		Testing and adjusting air conditioner compressor belt tension....................318
		Testing clearance of swing circle bearing........................................319
		Testing and adjusting track shoe tension.........................................320
		Testing and adjusting work equipment, swing, and travel circuit oil pressures....321
		Testing and adjusting control circuit oil pressure...............................326
		Testing and adjusting piston pump control oil pressure...........................328
		Testing servo piston stroke......................................................334
		Measuring PPC valve output pressure..............................................335
		Measuring outlet pressures of solenoid valve and PPC shuttle valve...............340
		Adjusting work equipment, swing PPC valve........................................346
		Testing and adjusting travel deviation...........................................347
		Measuring fan speed..............................................................349
		Measuring fan circuit oil pressure...............................................349
		Inspection of locations of hydraulic drift of work equipment.....................350
		Measuring oil leakage............................................................351
		Releasing remaining pressure in hydraulic circuit................................355
		Bleeding air from each part......................................................356
		Inspection procedures for diode..................................................359
30 Testing and adjusting.................................................................361
	Testing and adjusting, Part 2........................................................362
		Special function of machine monitor..............................................362
		Handling engine controller high voltage circuit..................................394
		Preparation work for troubleshooting electrical system...........................395
		Pm-CLINIC SERVICE................................................................397
		Pm-CLINIC SERVICE PC600, 600LC-8.................................................402
		UNDERCARRIAGE INSPECTION.........................................................403
40 Troubleshooting.......................................................................405
	General information on troubleshooting...............................................406
		Points to remember when troubleshooting..........................................406
		Sequence of events in troubleshooting............................................407
		Checks before troubleshooting....................................................408
		Classification and procedures of troubleshooting.................................409
		Connection table for connector pin numbers.......................................413
		T-boxes and T-adapters table.....................................................436
40 Troubleshooting.......................................................................441
	Troubleshooting by failure code (Display of code), Part 1............................444
40 Troubleshooting.......................................................................505
	Troubleshooting by failure code (Display of code), Part 2............................508
40 Troubleshooting.......................................................................571
	Troubleshooting by failure code (Display of code), Part 3............................574
40 Troubleshooting.......................................................................643
	Troubleshooting of electrical system (E-mode)........................................646
40 Troubleshooting.......................................................................703
	Troubleshooting of hydraulic and mechanical system (H-mode)..........................705
40 Troubleshooting.......................................................................745
	Troubleshooting of engine (S-mode)...................................................747
50 Disassembly and assembly..............................................................773
	General information on disassembly and assembly......................................774
		How to read this manual..........................................................774
		Coating materials list...........................................................776
		Special tools list...............................................................779
		Sketches of special tools........................................................785
50 Disassembly and assembly..............................................................791
	Engine and cooling system, Part 1....................................................792
		Removal and installation of engine, PTO and hydraulic pump assembly..............792
		Removal and installation of radiator assembly....................................799
		Removal and installation of hydraulic oil cooler assembly........................801
		Removal and installation of aftercooler assembly.................................803
		Removal and installation of fan motor assembly...................................805
		Removal and installation of fuel tank assembly...................................809
50 Disassembly and assembly..............................................................811
	Engine and cooling system, Part 2....................................................812
		Removal and installation of fuel supply pump assembly............................812
		Removal and installation of cylinder head assembly...............................817
		Removal and installation of fuel injector assembly...............................833
		Removal and installation of engine front seal....................................836
		Removal and installation of engine rear seal.....................................838
50 Disassembly and assembly..............................................................843
	Power train..........................................................................844
		Removal and installation of PTO assembly.........................................844
		Disassembly and assembly of PTO assembly.........................................846
		Removal and installation of swing motor and swing machinery assembly.............849
		Disassembly and assembly of swing machinery assembly.............................850
		Removal and installation of swing circle assembly................................857
		Disassembly and assembly of final drive assembly.................................858
50 Disassembly and assembly..............................................................869
	Undercarriage and frame..............................................................870
		Removal and installation of revolving frame assembly.............................870
		Disassembly and assembly of 1 link in field......................................872
		Removal and installation of idler, recoil spring assembly........................876
		Disassembly and assembly of idler assembly.......................................877
		Disassembly and assembly of recoil spring assembly...............................880
		Removal and installation of track roller assembly................................882
		Disassembly and assembly of track roller assembly................................883
		Removal and installation of carrier roller assembly..............................886
		Disassembly and assembly of carrier roller assembly..............................887
		Removal and installation of revolving frame assembly.............................890
		Removal and installation of counterweight assembly...............................892
		Removal and installation of counterweight remover assembly.......................893
50 Disassembly and assembly..............................................................897
	Hydraulic system.....................................................................898
		Removal and installation of hydraulic tank assembly..............................898
		Removal and installation of hydraulic pump assembly..............................900
		Removal and installation of control valve and solenoid valve assembly............903
		Disassembly and assembly of control valve assembly...............................905
		Disassembly and assembly of main control valve assembly..........................906
		Removal and installation of swing motor assembly.................................910
		Removal and installation of center swivel joint assembly.........................911
		Disassembly and assembly of center swivel joint assembly.........................912
		Disassembly and assembly of work equipment PPC valve assembly....................913
		Disassembly and assembly of travel PPC valve assembly............................915
		Disassembly and assembly of hydraulic cylinder assembly..........................917
50 Disassembly and assembly..............................................................923
	Work equipment.......................................................................924
		Removal and installation of bucket cylinder assembly.............................924
		Removal and installation of arm cylinder assembly................................926
		Removal and installation of boom cylinder assembly...............................928
		Removal and installation of bucket assembly......................................930
		Removal and installation of arm assembly.........................................932
		Removal and installation of boom assembly........................................934
50 Disassembly and assembly..............................................................937
	Cab and its attachments..............................................................938
		Removal and installation of operator’s cab.......................................938
		Removal and installation of operator’s cab glass (stuck glass)...................941
		Removal and installation of front window assembly................................951
50 Disassembly and assembly..............................................................957
	Electrical system....................................................................958
		Removal and installation of air conditioner unit assembly........................958
		Removal and installation of engine controller assembly...........................960
		Removal and Installation of KOMTRAX terminal assembly............................962
		Removal and installation of pump controller......................................962
		Removal and installation of monitor assembly.....................................963
90 Diagrams and drawings.................................................................965
	Hydraulic circuit diagram............................................................967
90 Diagrams and drawings.................................................................971
	Electrical circuit diagram (1/5).....................................................973
	Electrical circuit diagram (2/5).....................................................975
	Electrical circuit diagram (3/5).....................................................977
	Electrical circuit diagram (4/5).....................................................979
	Electrical circuit diagram (5/5).....................................................981
	Electrical circuit diagram for air conditioner.......................................983

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