Komatsu PC600-6,PC600LC-6 Hydraulic Excavator Shop Manual SEBM017111 PDF

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Komatsu PC600-6,PC600LC-6 Hydraulic Excavator Shop Manual SEBM017111 –  PDF DOWNLOAD

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Komatsu PC600-6,PC600LC-6 Hydraulic Excavator Shop Manual SEBM017111 –  PDF DOWNLOAD

Language : English
Pages : 1041
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC600-6,PC600LC-6 Hydraulic Excavator Shop Manual SEBM017111 –  PDF DOWNLOAD

MACHINE MODEL            SERIAL NUMBER

• PC600-6                              10001 and up
• PC600LC-6                          10001 and up

COVER PAGE . 1
CONTENTS . 2
LIST OF REVISED PAGES 3
01 GENERAL . 29
SPECIFICATIONS 30
WEIGHT TABLE 40
FUEL, COOLANT AND LUBRICANTS 44
10 STRUCTURE AND FUNCTION . 45
PARTS RELATED TO ENGINE . 46
PTO . 48
RADIATOR, OIL COOLER 49
POWER TRAIN . 50
FINAL DRIVE . 52
SWING CIRCLE 53
SWING MACHINERY . 54
TRACK FRAME, RECOIL SPRING 55
TRACK SHOE 56
HYDRAULIC PIPING DRAWING 58
HYDRAULIC TANK, HYDRAULIC FILTER 60
HYDRAULIC PUMP (PISTON PUMP) 63
SERVO VALVE . 66
TVC VALVE . 73
CO+NC VALVE . 79
SERVO VALVE (NO.2 FRONT) 89
LINE OIL FILTER . 91
CONTROL VALVE . 92
TRAVEL SHUTTLE VALVE 98
STRAIGHT-TRAVEL VALVE . 101
SWING PRIORITY VALVE 103
ARM THROTTLE VALVE 105
SWING MOTOR . 107
SWING BRAKE . 111
SAFETY VALVE 112
REVERSE PREVENTION VALVE 114
CENTRAL SWIVEL JOINT 117
TRAVEL MOTOR 118
PARKING BRAKE . 122
VALVE CONTROL . 128
WORK EQUIPMENT – SWING PPC VALVE 130
TRAVEL PPC VALVE 134
SERVICE PPC VALVE . 138
PPC SAFETY LOCK VALVE . 141
PPC ACCUMULATOR . 141
PPC SHUTTLE VALVE . 142
SOLENOID VALVE 143
BUCKET CURL HI CANCEL . 145
BOOM HOLDING VALVE 146
BOOM LOWER REGENERATION VALVE . 150
AIR CONDITIONER . 153
ACTUAL ELECTRIC WIRING DIAGRAM 154
ENGINE CONTROL 162
MACHINE CONTROL SYSTEM 173
MACHINE CONTROL SYSTEM DIAGRAM 174
MONITOR SYSTEM 208
20 TESTING AND ADJUSTING 225
STANDARD VALUE TABLE FOR ENGING . 226
STANDARD VALUE TABLE FOR CHASSIS 229
STANDARD VALUE TABLE FOR ELECTRICAL PARTS . 239
TESTING AND ADJUSTING . 257
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 258
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 259
MEASURING EXHAUST TEMPERATURE . 260
MEASURING EXHAUST COLOR . 261
ADJUSTING VALVE CLEARANCE . 262
MEASURING COMPRESSION PRESSURE 263
MEASURING BLOW-BY PRESSURE 263
MEASURING ENGINE OIL PRESSURE . 264
HANDLING EQUIPMENT IN FUEL CIRCUIT 265
RELEASING REMAINING PRESSURE IN FUEL SYSTEM . 265
MEASURING FUEL PRESSURE . 266
REDUCED CYLINDER OPERATION FOR ENGINE . 267
BLEEDING AIR FROM FUEL SYSTEM . 269
CHECK FOR LEAKAGE IN FUEL SYSTEM 270
ADJUSTING ENGINE SPEED SENSORY 271
TESTING AND ADJUSTING ALTERNATOR BELT TENSION . 272
TESTING AND ADJUSTING FAN BELT TENSION 273
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT . 274
TESTING AND ADJUSTING AIR CONDITIONAL COMPRESSOR DRIVE BELT TENSION . 275
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE . 276
TESTING WEAR OF SPROCKET 277
TESTING AND ADJUSTING TRACK SHOE TENSION 278
TESTING CLEARANCE OF SWING CIRCLE BEARING . 279
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT . 280
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE . 283
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE 285
MEASURING PPC VALVE OUTPUT PRESSUSRE 291
TESTING SOLENOID VALVE OUTPUT PRESSURE 292
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE . 293
TESTING TRAVEL DEVIATION 294
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT . 295
MEASURING OIL LEAKAGE . 296
BLEEDING AIR 299
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT . 301
PROCEDURE FOR CHECKING DIODE 302
TROUBLESHOOTING . 303
POINTS TO REMEMBER WHEN TROUBLESHOOTING . 304
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 305
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 306
CHECKS BEFORE TROUBLESHOOTING . 314
CONNECTOR TYPES AND MOUNTING LOCATIONS 316
CONNECTOR ARRANGEMENT DIAGRAM . 318
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 330
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM 354
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL . 357
TABLE OF MONITORING CODES . 362
TABLE OF SERVICE CODES 375
TABLE 1 OF MONITORING CODES (ALL CODES) . 379
TABLE 2 OF MONITORING CODES (DETAILS OF BIT PATTERN CODE) . 380
METHOD OF USING JUDGEMENT TABLE . 387
METHOD OF USING TROUBLESHOOTING CHARTS 391
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE 395
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (n MODE) 405
N-1(E218) COMMUNICATION ABNORMALITY . 406
TROUBLESHOOTING OF CUMMUNICATION ABNORMALITY SYSTEM (N MODE) 409
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 410
ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM . 412
N-1 [E117, E118 OCCUR AT SAME TIME] MONITOR PANEL COMMUNICATION ABNORMALITY . 413
N-2 [E117, E218 OCCUR AT SAME TIME] ENGINEER CONTROLLER COMMUNICATION ABNORMALITY . 415
N-3 [E118, E955 OCCUR AT SAME TIME] PUMP CONTROLLER COMMUNICATION ABNORMALITY . 417
TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM0, ENGING CONTROL SYSTEM (E MODE) 419
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER SYSTEM 420
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 422
JUDGEMENT TABLE FOR ENGINE THROTTLE & PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS 426
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM 428
E-1 ABNORMALITY IN ENGINE THROTTLE & PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF) . 430
E-2 [E308] (ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE) IS DISPLAYED 431
E-3 [E317] (ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM) IS DISPLAYED . 432
E-4 [E318] (ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED 433
E-5 [E306] (ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM) IS DISPLAYED 434
E-6 [E315] (ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM) IS DISPLAYED 435
E-7 [E316] (ABNORMALITY (STEP-0UT) IN MOTOR) IS DISPLAYED . 436
E-8 ENGINE SPEED IS IRREGULAR . 438
E-9 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW) 442
E-10 ENGINE DOES NOT START 444
E-11 ENGINE DOES NOT STOP (DEFECT IN ENGINE STOP SOLENOID SYSTEM) . 447
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (MONITOR PANEL, CONTROLLER DO NOT STOP) 448
E-13 ENGINE DOES NOT STOP . 450
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE) 451
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED 452
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS 460
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM . 462
E-1 [E91b] (ABNORMALITY IN ENGINE SPEED NE SENSOR SYSTEM) IS DISPLAYED 464
E-2 [E91C] (ABNORMALITY IN ENGINE G ROTATION SENSOR SYSTEM) IS DISPLAYED 465
E-3 [E920] (ABNORMALITY IN MODEL SELECTION SYSTEM) IS DISPLAYED . 466
E-4 [E922] (ENGINE OVERRUN) IS DISPLAYED 467
E-5 [E924] (DROP IN ENGINE OIL PRESSURE IS DISPLAYED 468
E-6 [E931] (ABNORMALITY IN FUEL CONTROL DIAL SENSOR SYSTEM) IS DISPLAYED 469
E-7 [E934] (ABNORMALITY IN ENGINE WATER TEMPERATURE 9HIGH) SENSOR SYSTEM) IS DISPLAYED 470
E-8 [E936] (ABNORMALITY IN ENGINE OIL PRESSURE SWITCH SYSTEM) IS DISPLAYED 471
E-9 [E93C] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM) IS DISPLAYED . 472
E-10 [E93d] 9ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED 473
E-11 [E954] (SHORT CIRCUIT IN STARTING SWITCH C SYSTEM) IS DISPLAYED 474
E-12 [E955] (ABNORMALITY IN NETWORK SYSTEM) IS DISPLAYED 474
E-13 [E956] (POWER SOURCE SYSTEM ABNORMALITY 1) IS DISPLAYED 475
E-14 [E957] (POWER SOURCE SYSTEM ABNORMALITY 2) IS DISPLAYED 476
E-15 [E95A] (ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL) IS DISPLAYED . 477
E-16 [E96A} (ABNORMALITY IN ENGINE WATER TEMPERATURE (LOW) SENSOR SYSTEM) IS DISPLAYED 478
E-17 [E970] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED . 479
E-18 [E971] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED . 480
E-19 [E974] (DISCONNECTION IN FUEL SUPPLY PUMP PCV 1 SYSTEM) IS DISPLAYED . 481
E-20 [E975] (DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED 482
E-21 [E977] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM) IS DISPLAYED . 483
E-22 [E979] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1) IS DISPLAYED . 484
E-22 [E97A] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2) IS DISPLAYED . 484
E-23 [E97b] (FUEL SUPPLY PUMP NON-FORCE FEED 1) IS DISPLAYED 485
E-23 [E97C] (FUEL SUPPLY PUMP NON-FORCE FEED 2) IS DISPLAYED 485
E-24 [E97d] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE) IS DISPLAYED . 487
E-25 [E980] (DEFECTIVE ENGINE CONTROLLER) IS DISPLAYED 487
E-26 [E981] (DISCONNECTION IN NO. 1 FUEL INJECTOR SYSTEM) IS DISPLAYED 488
E-27 [E982] (DISCONNECTION IN NO. 2 FUEL INJECTOR SYSTEM) IS DISPLAYED 489
E-28 [E983] (DISCONNECTION IN NO. 3 FUEL INJECTOR SYSTEM) IS DISPLAYED 490
E-29 [E984] (DISCONNECTION IN NO. 4 FUEL INJECTOR SYSTEM) IS DISPLAYED . 491
E-30 [E985] (DISCONNECTION IN NO. 5 FUEL INJECTOR SYSTEM) IS DISPLAYED 492
E-31 [E986] (DISCONNECTION IN NO. 6 FUEL INJECTOR SYSTEM) IS DISPLAYED 493
E-32 [E98A] (SHORT CIRCUIT IN NO. 1, NO. 2, NO. 3 FUEL INJECTOR SYSTEM) IS DISPLAYED 494
E-33 [E98b] (SHORT CIRCUIT IN NO. 3, NO. 4, NO. 5 FUEL INJECTOR SYSTEM,) IS DISPLAYED . 497
TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROL SYSTEM) (C MODE) 501
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM 502
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 504
JUDGEMENT TABLE FOR ENGINE THROTTLE & PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS . 510
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE . 512
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF) . 514
C-2 [E232] (SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED . 515
C-3 [E233] (DISCONNECTION IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED . 517
C-4 [E203] (SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED 519
C-5 [E213] (DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM) IS DISPLAYED 521
C-6 [E201] (SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED . 523
C-7 [E211] (DISCONNECTION IN C0 CANCEL SOLENOID SYSTEM) IS DISPLATED 524
C-8 [E205] (SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED . 525
C-9 [E-215] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED 526
C-10 [E206] (SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED 527
C-11 [E216] (DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED 528
C-12 [E311] (SHORT CIRCUIT IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED . 529
C-13 [E312] (DISCONNECTION IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED . 530
C-14 [E217] (MODEL SELECTION INPUT ERROR) IS DISPLAYED 531
C-15 [E224] (ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED . 533
C-16 [E225] (ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED 534
C-17 [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM) IS DISPLAYED . 535
C-18 [E227] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 536
C-19 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED) . 537
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE) 539
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM 540
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 542
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS . 550
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM . 552
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF) . 554
C-2 [E232] (SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED . 555
C-3 [E233] (DISCONNECTION IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED . 557
C-4 [E203] (SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED 559
C-5 [E213] (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED 561
C-6 [E201] (SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM) IS DISPLAYED 563
C-7 [E211] (DISCONNECTION IN CO CANCEL SOLENOID SYSTEM) IS DISPLAYED 564
C-8 [E204] (SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED . 565
C-9 [E214] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED . 566
C-10 [E206] (SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED 567
C-11 [E-216] (DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED . 568
C-12 [E311] (SHORT CIRCUIT IN BUCKET CURL HI CANCELSOLENOID SYTEM) IS DISPLAYED . 569
C-13 [E312] (DISCONNECTION IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED . 570
C-14 [E-217] (MODEL SELECTION INPUT ERROR) IS DISPLAYED . 571
C-15 [E224] (ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED . 573
C-16 [E225] (ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED 574
C-17 [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM) IS DISPLAYED . 575
C-18 [E227] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 576
C-19 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED) . 577
C-20 [E207] SHORT CIRCUIT IN FLASHING LIGHT RELAY DRIVE SYSTEM IS DISPLAYED . 579
C-21 FLASHING LIGHT RELAY DOES NOT WORK . 580
C-22 [E231] ABNORMALITY (SHORT CIRCUIT) IN STEP LIGHT POWER SOURCE RETENTION RELAY OUTPUT SYSTEM IS DISPLAYED . 581
C-23 STEP LIGHT SWITCH DOES NOT WORK 582
C-24 [E302] SHORT CIRCUIT IN STEP LIGHT RELAY DRIVE SYSTEM IS DISPLAYED . 583
C-25 STEP LIGHT DOES NOT LIGHT UP . 584
C-26 [E228] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED . 585
TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE) . 587
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE . 588
F-1 BIT PATTERN 20-(1) (SWING OILS PRESSURE SWITCH) DOES NOT LIGHT UP . 590
F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP . 591
F-3 BIT PATTERN 20-3 (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP . 592
F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH ) DOES NOT LIGHT UP 593
F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DOES NOT LIGHT UP . 594
F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP 595
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP . 596
F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP 597
F-9 BIT PATTERN 21-(2) (SERVICE VALVE OIL PRESSURE SWITCH) DOES NOT LIGHT UP 598
F-10 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP . 599
F-11 BIT PATTERN 22-(5) (KEROSENE MODE CONNECTION) DOES NOT LIGHT UP 600
F-12 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP 601
TROUBLESHOOTING OF PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE) . 603
ELECTRICAL CIRCUIT DIAGRAM FOR F MOD 604
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH) DOES NOT LIGHT UP . 606
F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP . 607
F-3 BIT PATTERN 20-(3) (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP . 608
F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH) DOES NOT LIGHT UP . 609
F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DIES NOT LIGHT UP . 610
F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP 611
F-7 BIT PATTERN 21-(1) (BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP’ . 612
F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP 613
F-9 BIT PATTERN 21-(2) (SERVICE VALVE OIL PRESSURE SWITCH) DOES NOT LIGHT UP 614
F-10 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP . 615
F-11 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP 616
F-12 WHEN STEP LIGHT SWITCH IS ON, BIT PATTERN 24-(1) DOES NOT GO OUT . 617
F-13 WHEN HORN SWITCH IS ON, BIT PATTERN 24-(2) DOES NOT GO OUT . 618
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE) . 619
TABLE OF FAILURE MODES AND CAUSES . 620
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE) 622
WORK EQUIPMENT IS SLOW OR LACKS POWER . 623
HYDRAULIC CIRCUIT DIAGRAM AFTER INTERCHANGING HOSES . 624
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER 625
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS . 626
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE . 628
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP) 629
H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) IS SLOW OR LACKS PWOER . 630
H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL) 631
H-8 EXCESSIVE HYDRULIC DRIFT 631
H-9 EXCESSIVE TIME LAG 632
H-10 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION 632
H-11 IN COMPOUND OPERATIONS WITH SWING, WORK EQUIPMENT SPEED IS SLOW 633
H-12 IN COMPOUND OPERATIONS WITH BUCKET CURL, SWING AND OTHER WORK EQUIPMENT SPEEDS ARE SLOW 633
H-13 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS . 633
H-14 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRVELOPERATIONS 634
H-15 DEVIATION IS EXCESSIVE WHEN STARTING . 638
H-16 TRAVEL SPEED IS SLOW . 640
H-17 TRAVEL SPEED DOES NOT SWITCH . 641
H-18 TRAVEL DOES NOT MOVE (ONE SIDE ONLY) . 641
H-19 DOES NOT SWING . 642
H-20 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR 643
H-21 EXCESSIVE OVERRUN WHEN STOPPING SWING 644
H-22 EXCESSIVE SHOCK WHEN STOPPING SWING 645
H-23 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING . 645
H-24 EXCESSIVE HYDRAULIC DRIFT OF SWING . 646
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 647
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE . 650
ELECTRICAL CIRCUIT DIGRAM FOR M MODE SYSTEM . 652
M-1 [E101] ABNORMALITY IN ERROR DATA) IS DISPLAYED 654
M-1 [E-102] (ERROR IN CLOCK DATA) IS DISPLAYED 654
M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED 655
M-3 [E-104] (AIR CLEANER CLOGGING DETECTED) IS DISPLAYED 656
M-4 [E-106] (DROP IN ENGINE OIL PRESSURE DETECTED) IS DISPLAYED 656
M-5 [E-108] (ENGINE WATER TEMPERATURE 105 DEG. C DETECTED) IS DISPLAYED . 657
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS 658
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT 660
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL) 660
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH . 661
M-10 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH . 664
M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP) 666
M-12 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING) 668
M-13 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND. CAUTION ITEMS FLASHES BUT BUZZER DOES NOT SOUND . 672
M-14 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS . 672
M-15 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL) . 673
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE 674
M-17 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION) 674
M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL 675
M-19 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY . 675
M-20 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT graphic (SWING LOCK MONITOR) DOES NOT LIGHT UP . 676
M-21 SWING HOLDING BRAKE RELEASE SWITCH IS TURNED ON, BUT graphic (SWING LOCK MONITOR) DOES NOT FLASH . 676
M-22 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING . 677
M-23 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED 677
M-24 DEFECTIVE FUEL LEVEL SENSOR SYSTEM . 678
M-25 DEFECTIVE COOLAND TEMPERATURE SENSOR SYSTEM 679
M-26 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM . 680
M-27 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM 681
M-28 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM 682
M-29 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED (INCLUDE E112, E113) 684
M-30 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED (INCLUDE E114) 689
M-31 ELECTRIC GREASE GUN DOES NOT WORK 691
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 693
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE . 696
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM 698
M-1 [E101] ABNORMALITY IN ERROR DATA ) OR [E102] (ABNORMALITY IN CLOCK DATA) IS DISPLAYED . 700
M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT SYSTEM) IS DISPLAYED . 701
M-3 [E-104] (AIR CLEANER CLOGGING DETECTION) IS DISPLAYED . 702
M-4 [E108] (ENGINE WATER TEMPERATURE 105 DEG. C) IS DISPLAYED . 702
M-5 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS 703
M-6 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT 705
M-7 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE 705
M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH . 706
M-9 PREHEATING IS NOT BEING USED BUT PREHEATING DISPLAY MONITOR LAMP LIGHTS UP 709
M-10 WHEN ENGINE IS STARTED, BASIC CHECK ITEMS FLASH 710
M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH . 711
M-12 WHEN ENGINE IS STARTED, CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH . 712
M-13 OPERATION OF ALARM BUZZER IS NOT NORMAL 716
M-14 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP 718
M-15 ENGINE WATER TEMPERATURE DISPLAY IS NOT NORMAL . 719
M-16 FUEL LEVEL GAUGE DISPLAY IS NOT NORMAL . 720
M-17 SWING LOCK SWITCH IS TURNED ON BUT SWING LOCK MONITOR LAMP DOES NOT LIGHT UP . 722
M-18 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL (EMERGENCY), SWING LOCK MONITOR LAMP DOES NOT FLASH 723
M-19 SERVICE METER DOES NOT GIVE NORMAL DISPLAY . 724
M-20 DEFECTIVE FUEL LEVEL SENSOR SYSTEM . 725
M-21 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM . 726
M-22 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM 727
M-23 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM 728
M-24 WIPER IS NOT ACTUATED WHEN WIPER SWITCH IS OPERATED OR WIPER IS ACTUATED WHEN WIPER SWITCH IS NOT OPERATED . 729
M-25 WINDOW WASHER IS NOT ACTUATED WHEN SWITCH IS OPERATED OR WINDOW WASHER IS ACTUATED WHEN SWITCH IS NOT OPERATED . 734
M-26 ELECTRIC GREASE GUN DOES NOT WORK (MACHINES EQUIPPED WITH ELECTRIC GREASE GUN) . 737
30 DISASSEMBLY AND ASSEMBLY . 739
METHOD OF USING MANUAL 742
PRECAUTIONS WHEN CARRYING OUT OPERATION . 745
SPECIAL TOOL LIST . 747
SKETCHES OF SPECIAL TOOLS . 757
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY 766
REMOVAL OF FUEL SUPPLY PUMP ASSEMBLY 767
INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY . 769
REMOVAL OF FUEL INJECTOR ASSEMBLY . 770
INSTALLATION OF FUEL INJECTOR ASSEMBLY 772
REMOVAL OF NOZZLE TIP . 774
INSTALLATION OF NOZZLE TIP 775
REMOVAL OF ENGINE FRONT SEAL 775
INSTALLATION OF ENGINE FRONT SEAL . 777
REMOVAL OF ENGINE REAR SEAL . 779
INSTALLATION OF ENGINE REAR SEAL 780
REMOVAL OF CYLINDER HEAD ASSEMBLY . 784
INSTALLATION OF CYLINDER HEAD ASSEMBLY 787
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY 791
INSTALLATION OF RADIATOR, HYDRUALIC COOLER ASSEMBLY . 792
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY 793
INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY . 794
REMOVAL OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY . 796
INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY 799
REMOVAL OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY . 800
INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY 803
REMOVAL OF PTO ASSEMBLY . 804
INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY 804
DISASSEMBLY OF PTO ASSEMBLY . 805
ASSEMBLY OF PTO ASSEMBLY 807
REMOVAL OF FUEL TANK ASSEMBLY . 809
INSTALLATION OF FUEL TANK . 809
REMOVAL OF FUEL TANK ASSEMBLY . 810
INSTALLATION OF FUEL TANK . 810
DISASSEMBLY OF FINAL DRIVE ASSEMBLY . 812
ASSEMBLY OF FINAL DRIVE ASSEMBLY 818
REMOVAL OF REVOLVING FRAME ASSEMBLY . 826
INSTALLATION OF REVOLVING FRAME ASSEMBLY 827
REMOVAL OF SWING MOTOR ASSEMBLY . 828
INSTALLATION OF SWING MOTOR ASSEMBLY 828
DISASSEMBLY OF SWING MOTOR ASSEMBLY . 829
ASSEMBLY OF SWING MOTOR ASSEMBLY 833
REMOVAL OF SWING MACHINERY ASSEMBLY . 841
INSTALLATION OF SWING MACHINERY ASSEMBLY 841
DISASSEMBLY OF SWING MACHINERY ASSEMBLY . 842
ASSEMBLY OF SWING MACHINERY ASSEMBLY 846
REMOVAL OF SWING CIRCLE ASSEMBLY 851
INSTALLATION OF SWING CIRCLE ASSEMBLY . 851
REMOVAL OF TRACK SHOE ASSEMBLY 852
INSTALLATION OF TRACK SHOE ASSEMBLY . 853
DISASSEMBLY OF ONE LINK IN FIELD 854
ASSEMBLY OF ONE LINK IN FIELD . 856
REMOVAL OF IDLER, RECOIL SPRING ASSEMBLY 858
INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY . 858
DISASSEMBLY OF IDLER ASSEMBLY . 859
ASSEMBLY OF IDLER ASSEMBLY 861
DISASSEMBLY OF RECOIL SPRING ASSEMBLY . 863
ASSEMBLY OF RECOIL SPRING ASSEMBLY 864
REMOVAL OF TRACK ROLLER ASSEMBLY 865
INSTALLATION OF TRACK ROLLER ASSEMBLY . 865
DISASSEMBLY OF TRACK ROLLER ASSEMBLY 866
ASSEMBLY OF TRACK ROLLER ASSEMBLY . 867
REMOVAL OF CARRIER ROLLER ASSEMBLY 869
INSTALLATION OF CARRIER ROLLER ASSEMBLY . 869
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY 870
ASSEMBLY OF CARRIER ROLLER ASSEMBLY . 871
REMOVAL OF HYDRAULIC TANK ASSEMBLY 873
INSTALLATION OF HYDRAULIC TANK ASSEMBLY . 874
DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY . 876
ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY 877
REMOVAL OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY 878
INSTALLATION OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY . 879
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY 880
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY . 882
REMOVAL OF NO. 1 AND NO. 2 PUMP ASSEMBLY 884
INSTALLATION OF NO. 1 AND NO. 2 PUMP ASSEMBLY . 885
DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY 886
ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY . 896
REMOVAL OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY . 912
INSTALLATION OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY 912
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY . 913
INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY 913
DISASSEMBLY OF CENTER SWIVEL JOING ASSEMBLY . 914
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 914
DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY 915
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY . 916
DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 917
ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY . 918
REMOVAL OF BUCKET CYLINDER ASSEMBLY . 919
INSTALLATION OF BUCKET CYLINDER ASSEMBLY 920
REMOVAL OF ARM CYLINDER ASSEMBLY 921
INSTALLATION OF ARM CYLINDER ASSEMBLY . 922
REMOVAL OF BOOM CYLINDER ASSEMBLY . 923
INSTALLATION OF BOOM CYLINDER ASSEMBLY 924
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 925
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY . 928
REMOVAL OF BUCKET ASSEMBLY 932
INSTALLATION OF BUCKET ASSEMBLY . 933
REMOVAL OF ARM ASSEMBLY . 934
INSTALLATION OF ARM ASSEMBLY 935
REMOVAL OF BOOM ASSEMBLY 936
INSTALLATION OF BOOM ASSEMBLY . 937
REMOVAL OF OPERATOR’S CAB ASSEMBLY 938
INSTALLATION OF OPERATOR’S CAB ASSEMBLY . 939
REMOVAL OF COUNTERWEIGHT ASSEMBLY . 940
INSTALLATION OF COUNTERWEIGHT ASSEMBLY 940
40 MAINTENANCE STANDARD . 941
ENGINE MOUNT 942
PTO . 943
SWING MACHINERY . 944
SWING CIRCLE 946
FINAL DRIVE . 948
TRACK FRAME AND RECOIL SPRING . 950
IDLER . 952
CARRIER ROLLER 954
TRACK ROLLER 955
TRACK SHOE 956
DOUBLE SHOE . 959
TRIPLE GROUSER SHOE . 960
HYDRAULIC PUMP 961
CONTROL AND PTO LUBRICATION PUMP 963
CONTROL VALVE . 964
SWING MOTOR . 971
TRAVEL MOTOR 972
WORK EQUIPMENT – SWING PPC VALVE 973
TRAVEL PPC VALVE 974
SERVICE PPC VALVE . 975
SOLENOID VALVE 976
CENTER SWIVEL JOINT . 977
BOOM HOLDING VALVE 978
BOOM LOWER REGENERATION VALVE . 979
HYDRAULIC CYLINDER 980
BACKHOE SPECIFICATION . 980
BOOM CYLINDER . 980
ARM CYLINDER 980
BUCKET CYLINDER . 980
LOADING SHOVEL SPECIFICATION 982
BOOM CYLINDER . 982
ARM CYLINDER 982
BUCKET CYLINDER . 982
BOTTOM DUMP CYLINDER 983
WORK EQUIPMENT 984
BACKHOE SPECIFICATION . 984
LOADING SHOVEL SPECIFICATION 986
DIMENSIONS OF WORK EQUIPMENT 988
BACKHOE SPECIFICATION . 988
ARM . 988
BUCKET 990
90 OTHERS . 993
HYDRAULIC CIRCUIT DIAGRAM (2/2) . 995
HYDRAULIC CIRCUIT DIAGRAM (1/2) .1000
HYDRAULIC CIRCUIT DIAGRAM (2/2) .1005
ELECTRIC CIRCUIT DIAGRAM (1/3) 1006
ELECTRIC CIRCUIT DIAGRAM (2/3) 1011
ELECTRIC CIRCUIT DIAGRAM (3/3) 1016
ELECTRIC CIRCUIT DIAGRAM (1/4) 1021
ELECTRIC CIRCUIT DIAGRAM (2/4) 1026
ELECTRIC CIRCUIT DIAGRAM (3/4) 1031
ELECTRIC CIRCUIT DIAGRAM (4/4) 1036

DESCRIPTION:

Komatsu PC600-6,PC600LC-6 Hydraulic Excavator Shop Manual SEBM017111 –  PDF DOWNLOAD

MACHINE MODEL            SERIAL NUMBER

• PC600-6                              10001 and up
• PC600LC-6                          10001 and up

G.B 28/12/24