Komatsu HYDRAULIC EXCAVATOR PC600 -8R PC600LC-8R Shop Manual SEN02402-19 -PDF  DOWNLOAD

Description

Komatsu HYDRAULIC EXCAVATOR PC600 -8R PC600LC-8R Shop Manual SEN02402-19 -PDF  DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC EXCAVATOR PC600 -8R PC600LC-8R Shop Manual SEN02402-19 -PDF  DOWNLOAD

Language : English
Pages :1066
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC600 -8R PC600LC-8R Shop Manual SEN02402-19 -PDF  DOWNLOAD

SERIAL NUMBERS 60001 and up

1. General precautions 

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC600 -8R PC600LC-8R Shop Manual SEN02402-19 -PDF  DOWNLOAD

SERIAL NUMBERS 60001 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 15
Safety notice 16
How to read the shop manual 21
Explanation of terms for maintenance standard 23
Handling of electric equipment and hydraulic component 25
Handling of connectors newly used for engines 34
How to read electric wire code 37
Precautions when carrying out operation 40
Method of disassembling and connecting push-pull type coupler 43
Standard tightening torque table 46
Conversion table 50
01 Specification 57
Specification and technical data 57
Specification drawings 58
Working range drawings 60
Specifications 62
Weight table 70
Table of fuel, coolant and lubricants 74
10 Structure, function and maintenance standard 77
Engine and cooling system 77
Parts related to engine 78
PTO 80
Fan, control and PTO lubrication pump 82
Radiator, oil cooler 83
Power train 85
Power train 86
Final drive 89
Sprocket 92
Swing circle 94
Swing machinery 96
Undercarriage and frame 99
Track frame, recoil spring 100
Idler 102
Carrier roller 104
Track roller 105
Track shoe 106
Hydraulic system, Part 1 113
Hydraulic piping drawing 114
Hydraulic tank, hydraulic filter 116
Hydraulic pump (piston pump) 118
Line oil filter 146
Cooling fan pump 148
Cooling fan motor 156
Hydraulic system, Part 2 163
Control valve 164
Swing motor 183
Swing brake 186
Safety valve 187
Reverse prevention valve 189
Center swivel joint 192
Travel motor 193
Parking brake 198
Brake valve 200
Set pressures varying mechanism 203
Valve control 204
Work equipment, swing PPC valve 206
Travel PPC valve 210
Service PPC valve 212
PPC accumulator 213
PPC shuttle valve 214
Solenoid valve 215
Boom holding valve 220
Boom LOWER regeneration valve 224
Quick return valve 227
Hydraulic cylinder 230
Work equipment 235
Work equipment 236
Dimensions of work equpment 240
Cab and its attachments 245
Air conditioner piping 246
Electrical system 249
Engine control 250
Machine control system diagram 255
Monitor system 279
Sensors 294
KOMTRAX system 298
20 Standard value table 301
Standard service value table 301
Standard value table for engine 302
Standard value table for chassis 303
30 Testing and adjusting 325
Testing and adjusting, Part 1 325
Tools for testing, adjusting and troubleshooting 327
Measuring engine speed 332
Measuring intake air pressure (boost pressure) 333
Measuring exhaust gas temperature 334
Measuring exhaust gas color 335
Adjusting valve clearance 336
Measuring compression pressure 337
Measuring blow-by pressure 339
Measuring engine oil pressure 339
Handling equipment in fuel circuit 340
Releasing remaining pressure in fuel system 340
Measuring fuel pressure 341
Reduced cylinder mode operation 342
No-injection cranking 342
Testing leakage from pressure limiter and return rate from injector 343
Bleeding air from fuel circuit 346
Testing fuel system for leakage 348
Testing and adjusting alternator belt tension 349
Testing and adjusting air conditioner compressor belt tension 350
Testing clearance of swing circle bearing 351
Testing and adjusting track shoe tension 352
Testing and adjusting work equipment, swing, and travel circuit oil pressures 353
Testing and adjusting control circuit oil pressure 358
Testing and adjusting piston pump control oil pressure 360
Testing servo piston stroke 366
Measuring PPC valve output pressure 367
Measuring outlet pressures of solenoid valve and PPC shuttle valve 371
Adjusting work equipment, swing PPC valve 377
Testing and adjusting travel deviation 378
Measuring fan speed 380
Measuring fan circuit oil pressure 381
Inspection of locations of hydraulic drift of work equipment 382
Measuring oil leakage 383
Releasing remaining pressure in hydraulic circuit 387
Bleeding air from each part 388
Inspection procedures for diode 391
Testing and adjusting, Part 2 393
Special function of machine monitor 394
Handling controller voltage circuit 428
Procedure for turning on KOMTRAX terminal 429
KOMTRAX terminal lamp indications 432
Preparation work for troubleshooting electrical system 435
Adjusting mirrors 437
Pm-CLINIC SERVICE 438
Pm-CLINIC SERVICE PC600, 600LC-8R 443
UNDERCARRIAGE INSPECTION 444
40 Troubleshooting 447
Failure code table and fuse locations 447
Failure codes table 448
Fuse locations 452
General information on troubleshooting 455
Points to remember when troubleshooting 456
Sequence of events in troubleshooting 457
Checks before troubleshooting 458
Classification and procedures of troubleshooting 459
Connection table for connector pin numbers 465
T- branch box and T- branch adapter table 501
Troubleshooting by failure code (Display of code), Part 1 505
Failure code [AA10NX] Aircleaner clogging 508
Failure code [AB00KE] Charge Voltage Low 510
Failure code [B@BAZG] Eng Oil Press Low 512
Failure code [B@BAZK] Eng Oil Level Low 514
Failure code [B@BCNS] Eng Water Overheat 515
Failure code [B@BCZK] Eng Water Lvl Low 516
Failure code [B@HANS] Hydr Oil Overheat 518
Failure code [CA111] ECM Critical Internal Failure 519
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 520
Failure code [CA122] Chg Air Press Sensor High Error 522
Failure code [CA123] Chg Air Press Sensor Low Error 524
Failure code [CA131] Throttle Sensor High Error 526
Failure code [CA132] Throttle Sensor Low Error 528
Failure code [CA135] Eng Oil Press Sensor High Error 530
Failure code [CA141] Eng Oil Press Sensor Low Error 532
Failure code [CA144] Coolant Temp Sens High Error 534
Failure code [CA145] Coolant Temp Sens Low Error 536
Failure code [CA153] Chg Air Temp Sensor High Error 538
Failure code [CA154] Chg Air Temp Sensor Low Error 540
Failure code [CA187] Sens Supply 2 Volt Low Error 540
Failure code [CA221] Ambient Press Sens High Error 542
Failure code [CA222] Ambient Press Sens Low Error 544
Failure code [CA227] Sens Supply 2 Volt High Error 546
Failure code [CA234] Eng Overspeed 548
Failure code [CA238] Ne Speed Sens Supply Volt Error 549
Failure code [CA263] Fuel Temp Sensor High Error 550
Failure code [CA265] Fuel Temp Sensor Low Error 552
Failure code [CA271] IMV/PCV1 Short Error 553
Failure code [CA272] IMV/PCV1 Open Error 554
Failure code [CA273] PCV2 Short Error 555
Failure code [CA274] PCV2 Open Error 556
Troubleshooting by failure code (Display of code), Part 2 559
Failure code [CA322] Inj #1 (L#1) Open/Short Error 561
Failure code [CA323] Inj #5 (L#5) Open/Short Error 562
Failure code [CA324] Inj #3 (L#3) Open/Short Error 564
Failure code [CA325] Inj #6 (L#6) Open/Short Error 566
Failure code [CA331] Inj #2 (L#2) Open/Short Error 568
Failure code [CA332] Inj #4 (L#4) Open/Short Error 570
Failure code [CA342] Calibration Code Incompatibility 571
Failure code [CA351] Injectors Drive Circuit Error 572
Failure code [CA352] Sens Supply 1 Volt Low Error 575
Failure code [CA386] Sens Supply 1 Volt High Error 576
Failure code [CA441] Battery Voltage Low Error 578
Failure code [CA442] Battery Voltage High Error 578
Failure code [CA449] Rail Press Very High Error 579
Failure code [CA451] Rail Press Sensor High Error 580
Failure code [CA452] Rail Press Sensor Low Error 582
Failure code [CA553] Rail Press High Error 582
Failure code [CA554] Rail Press Sensor In Range Error 583
Failure code [CA559] Rail Press Low Error 584
Failure code [CA689] Eng Ne Speed Sensor Error 588
Failure code [CA731] Eng Bkup Speed Sens Phase Error 590
Failure code [CA757] All Persistent Data Lost Error 590
Failure code [CA778] Engine Bkup Speed Sensor Error 592
Failure code [CA1633] KOMNET Datalink Timeout Error 594
Failure code [CA2185] Throt Sens Sup Volt High Error 596
Failure code [CA2186] Throt Sens Sup Volt Low Error 598
Failure code [CA2249] Rail Press Very Low Error 598
Failure code [CA2555] Grid Htr Relay Volt Low Error 599
Failure code [CA2556] Grid Htr Relay Volt High Error 600
Failure code [D110KB] Battery Relay Drive S/C 602
Failure code [D163KB] Flash Light Relay S/C 604
Failure code [D195KB] Step Light Relay S/C 606
Failure code [DA22KK] Pump Solenoid Power Low Error 608
Failure code [DA25KP] Press Sensor Power Abnormality 610
Failure code [DA2SKQ] Model Selection Abnormality 612
Failure code [DA80MA] Auto Lub Abnormal 614
Troubleshooting by failure code (Display of code), Part 3 617
Failure code [DA2RMC] Pump Comm Abnormality 620
Failure code [DAFRMC] Monitor Comm Abnormality 622
Failure code [DGE5KY] Ambi Temp Sensor S/C 624
Failure code [DGH2KB] Hydr Oil Temp Sensor S/C 625
Failure code [DHPAMA] F pump P Sensor Abnormality 626
Failure code [DHPBMA] R pump P Sensor Abnormality 628
Failure code [DV20KB] Travel Alarm S/C 630
Failure code [DW43KA] Travel Speed Sol Disc 632
Failure code [DW43KB] Travel Speed Sol S/C 634
Failure code [DW45KA] Swing Brake Sol Disc 636
Failure code [DW45KB] Swing Brake Sol S/C 638
Failure code [DW48KA] CO Cancel Sol Disc 640
Failure code [DW48KB] CO Cancel Sol S/C 642
Failure code [DW7BKA] Fan Reverse Sol Disc 644
Failure code [DW7BKB] Fan Reverse Sol S/C 645
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol Disc 646
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol S/C 648
Failure code [DWK0KA] 2-stage Relief Sol Disc 650
Failure code [DWK0KB] 2-stage Relief Sol S/C 652
Failure code [DX16KA] Fan Pump EPC Sol Disc 654
Failure code [DX16KB] Fan Pump EPC Sol S/C 656
Failure code [DXA0KA] TVC Sol Disc 658
Failure code [DXA0KB] TVC Sol S/C 660
Failure code [DY20KA] Wiper Working Abnormality 662
Failure code [DY20MA] Wiper Parking Abnormality 664
Failure code [DY2CKB] Washer Drive S/C 668
Failure code [DY2DKB] Wiper Drive (For) S/C 670
Failure code [DY2EKB] Wiper Drive (Rev) S/C 674
Troubleshooting of electrical system (E-mode) 677
E-1 Engine does not start (Engine does not rotate) 679
E-2 Preheater does not operate 682
E-3 Auto engine warm-up device does not work 684
E-4 Auto-decelerator does not operate 685
E-5 All work equipment, swing and travel do not move 686
E-6 Power max function does not operate 688
E-7 Machine push-up function does not operate normally 689
E-8 Any item is not displayed on machine monitor 691
E-9 Part of display on machine monitor is missing 692
E-10 Machine monitor displays contents irrelevant to the model 692
E-11 Fuel level monitor red lamp lights up while engine is running 693
E-12 Engine coolant temperature gauge does not display correctly 694
E-13 Hydraulic oil temperature gauge does not display correctly 696
E-14 Fuel gauge does not display correctly 697
E-15 Swing lock monitor does not display correctly 698
E-16 When monitor switch is operated, nothing is displayed 700
E-17 Wiper and window washer do not work 702
E-18 “Boom Raise” is not correctly displayed in monitoring function 710
E-19 “Boom Lower” is not correctly displayed in monitoring function 711
E-20 “Arm IN” is not correctly displayed in monitoring function 712
E-21 “Arm OUT” is not correctly displayed in monitoring function 713
E-22 “Bucket CURL” is not correctly displayed in monitoring function 714
E-23 “Bucket DUMP” is not correctly displayed in monitoring function 715
E-24 “Swing” is not correctly displayed in monitoring function 716
E-25 “Travel” is not correctly displayed in monitoring function 718
E-26 Air conditioner does not work 720
E-27 Step light does not light up or go off 722
E-28 Electric grease gun does not operate 726
E-29 Travel alarm does not sound or does not stop sounding 728
E-30 Electric priming pump does not operate or does not stop automatically 730
E-31 Horn does not sound 732
E-32 Bottom dump does not move 734
Troubleshooting of hydraulic and mechanical system (H-mode) 737
Before troubleshooting H-mode 739
Information in troubleshooting table 744
H-1 Speed or power of all work equipment, travel, and swing is low 746
H-2 Engine speed lowers remarkably or engine stalls 748
H-3 All work equipment, travel, and swing systems do not work 750
H-4 Abnormal sound is heard from around pump 752
H-5 Auto-decelerator is not reset 753
H-6 Boom speed or power is low 754
H-7 Arm speed or power is low 756
H-8 Bucket speed or power is low 757
H-9 Boom does not move 758
H-10 Arm does not move 758
H-11 Bucket does not move 759
H-12 Bottom dump does not move 759
H-13 Hydraulic drift of work equipment is large 760
H-14 Time lag of work equipment is large 761
H-15 Power max function does not operate or stop 762
H-16 Machine push-up function does not operate or stop 762
H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is low 763
H-17 When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel speed is low 763
H-19 When arm and swing are operated simultaneously, swing speed is low 764
H-20 Machine deviates in one direction 765
H-21 Machine deviates largely at start 767
H-22 Travel deviation is large during compound operation 768
H-23 Travel speed or power is low 769
H-24 Machine does not travel (only one track) 770
H-25 Travel speed does not change 771
H-26 Upper structure does not swing 772
H-27 Swing speed or acceleration is low 773
H-28 Upper structure overruns excessively when it stops swinging 774
H-29 Large shock is made when upper structure stops swinging 775
H-30 Large abnormal sound is made when upper structure stops swinging 776
H-31 Hydraulic drift of swing is large 777
Troubleshooting of engine (S-mode) 779
Method of using troubleshooting chart 781
S-1 Starting performance is poor 784
S-2 Engine does not start 785
S-3 Engine does not pick up smoothly 788
S-4 Engine stops during operations 789
S-5 Engine does not rotate smoothly 790
S-6 Engine lacks output (or lacks power) 791
S-7 Exhaust smoke is black (incomplete combustion) 792
S-8 Oil consumption is excessive (or exhaust smoke is blue) 793
S-9 Oil becomes contaminated quickly 794
S-10 Fuel consumption is excessive 795
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 796
S-12 Oil pressure drops 797
S-13 Oil level rises (Entry of coolant or fuel) 798
S-14 Coolant temperature becomes too high (overheating) 799
S-15 Abnormal noise is made 800
S-16 Vibration is excessive 801
S-17 Air cannot be bled from fuel circuit 802
50 Disassembly and assembly 805
General information on disassembly and assembly 805
How to read this manual 806
Coating materials list 808
Special tools list 811
Sketches of special tools 817
Engine and cooling system, Part 1 825
Removal and installation of engine, PTO and hydraulic pump assembly 826
Removal and installation of radiator assembly 834
Removal and installation of hydraulic oil cooler assembly 836
Removal and installation of aftercooler assembly 838
Removal and installation of fan motor assembly 840
Removal and installation of fuel tank assembly 844
Engine and cooling system, Part 2 847
Removal and installation of fuel supply pump assembly 848
Removal and installation of cylinder head assembly 853
Removal and installation of fuel injector assembly 868
Removal and installation of engine front seal 871
Removal and installation of engine rear seal 875
Power train 881
Removal and installation of PTO assembly 882
Disassembly and assembly of PTO assembly 884
Removal and installation of swing motor and swing machinery assembly 887
Disassembly and assembly of swing machinery assembly 888
Removal and installation of swing circle assembly 895
Disassembly and assembly of final drive assembly 896
Undercarriage and frame 907
Removal and installation of track shoe assembly 908
Disassembly and assembly of 1 link in field 910
Removal and installation of idler, recoil spring assembly 914
Disassembly and assembly of idler assembly 915
Disassembly and assembly of recoil spring assembly 918
Removal and installation of track roller assembly 920
Disassembly and assembly of track roller assembly 921
Removal and installation of carrier roller assembly 924
Disassembly and assembly of carrier roller assembly 925
Removal and installation of revolving frame assembly 928
Removal and installation of counterweight assembly 930
Hydraulic system 933
Removal and installation of hydraulic tank assembly 934
Removal and installation of hydraulic pump assembly 936
Removal and installation of control valve and solenoid valve assembly 940
Disassembly and assembly of control valve assembly 942
Disassembly and assembly of main control valve assembly 944
Removal and installation of swing motor assembly 948
Removal and installation of center swivel joint assembly 949
Disassembly and assembly of center swivel joint assembly 950
Disassembly and assembly of work equipment PPC valve assembly 952
Disassembly and assembly of travel PPC valve assembly 954
Disassembly and assembly of hydraulic cylinder assembly 957
Disassembly and assembly of grease gun assembly 963
Work equipment 965
Removal and installation of bucket cylinder assembly (Backhoe specification) 966
Removal and installation of bucket cylinder assembly (Loading shovel specification) 968
Removal and installation of arm cylinder assembly (Backhoe specification) 970
Removal and installation of arm cylinder assembly (Loading shovel specification) 972
Removal and installation of boom cylinder assembly (Backhoe specification) 974
Removal and installation of boom cylinder assembly (Loading shovel specification) 976
Removal and installation of bottom dump cylinder assembly (Loading shovel specification) 978
Removal and installation of bucket assembly (Backhoe specification) 979
Removal and installation of bucket assembly (Loading shovel specification) 981
Removal and installation of arm assembly (Backhoe specification) 982
Removal and installation of arm assembly (Loading shovel specification) 984
Removal and installation of boom assembly (Backhoe specification) 985
Removal and installation of boom assembly (Loading shovel specification) 987
Removal and installation of work equipment (Backhoe specification) 989
Removal and installation of work equipment (Loading shovel specification) 991
Cab and its attachments 995
Removal and installation of operator’s cab 996
Removal and installation of operator’s cab glass (stuck glass) 999
Removal and installation of front window assembly1008
Removal and installation of work equipment control lever assembly1013
Electrical system1027
Removal and installation of air conditioner unit assembly1028
Removal and installation of engine controller assembly1030
Removal and Installation of KOMTRAX terminal assembly1032
Removal and installation of pump controller assembly1032
Removal and installation of monitor assembly1033
90 Diagrams and drawings1035
Hydraulic diagrams and drawings1035
Hydraulic circuit diagram (1/4) (Backhoe specification)1037
Hydraulic circuit diagram (2/4) (ATT specification)1039
Hydraulic circuit diagram (3/4) (Loading shovel specification)1041
Hydraulic circuit diagram (4/4) (Loading shovel specification)1043
Electrical diagrams and drawings1047
Electrical circuit diagram (1/6)1049
Electrical circuit diagram (2/6)1051
Electrical circuit diagram (3/6)1053
Electrical circuit diagram (4/6)1055
Electrical circuit diagram (5/6)1057
Electrical circuit diagram (6/6)1059
Connector arrangement diagram1061
Electrical circuit diagram for air conditioner1063

IMAGES PREVIEW OF THE MANUAL:’

S.M 27/12/24