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Komatsu PC600-7 PC600LC-7 Service Repair Manual – PDF Download
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Description
Komatsu PC600-7 PC600LC-7 Service Repair Manual
KOMATSU PC600-7 PC600LC-7 SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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Table Of Contents:
Komatsu PC600-7 PC600LC-7 Service Repair Manual
COVER.............................................................................................................................. 1 CONTENTS........................................................................................................................... 2 01 GENERAL......................................................................................................................... 29 SPECIFICATION DRAWINGS......................................................................................................... 30 SPECIFICATIONS................................................................................................................. 32 WEIGHT TABLE................................................................................................................... 36 FUEL, COOLANT AND LUBRICANTS................................................................................................... 38 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.................................................................................... 39 PARTS RELATED TO ENGINE........................................................................................................ 40 PTO............................................................................................................................ 42 CONTROL AND PTO LUBRICATION PUMP............................................................................................... 44 RADIATOR, OIL COOLER........................................................................................................... 45 POWER TRAIN.................................................................................................................... 46 FINAL DRIVE.................................................................................................................... 48 SPROCKET....................................................................................................................... 49 SWING CIRCLE................................................................................................................... 53 SWING MACHINERY................................................................................................................ 54 TRACK FRAME, RECOIL SPRING..................................................................................................... 56 IDLER.......................................................................................................................... 58 CARRIER ROLLER................................................................................................................. 60 TRACK ROLLER................................................................................................................... 61 TRACK SHOE..................................................................................................................... 62 HYDRAULIC PIPING DRAWING....................................................................................................... 68 HYDRAULIC TANK, HYDRAULIC FILTER............................................................................................... 70 HYDRAULIC PUMP (PISTON PUMP)................................................................................................... 72 LINE OIL FILTER................................................................................................................100 CONTROL VALVE..................................................................................................................101 SWING MOTOR....................................................................................................................120 CENTER SWIVEL JOINT............................................................................................................129 TRAVEL MOTOR...................................................................................................................130 VALVE CONTROL..................................................................................................................141 WORK EQUIPMENT, SWING PPC VALVE................................................................................................142 TRAVEL PPC VALVE...............................................................................................................146 SERVICE PPC VALVE..............................................................................................................148 PPC ACCUMULATOR................................................................................................................149 PPC SHUTTLE VALVE..............................................................................................................150 SOLENOID VALVE.................................................................................................................151 BOOM HOLDING VALVE.............................................................................................................156 BOOM LOWER REGENERATION VALVE..................................................................................................160 HYDRAULIC CYLINDER.............................................................................................................163 WORK EQUIPMENT.................................................................................................................166 DIMENSIONS OF WORK EQUPMENT....................................................................................................168 COUNTERWEIGHT REMOVER..........................................................................................................172 AIR CONDITIONER................................................................................................................176 ENGINE CONTROL.................................................................................................................177 MACHINE CONTROL SYSTEM.........................................................................................................182 MONITOR SYSTEM.................................................................................................................207 SENSORS........................................................................................................................222 20 TESTING AND ADJUSTING...........................................................................................................226 STANDARD VALUE TABLE FOR ENGINE................................................................................................227 STANDARD VALUE TABLE FOR CHASSIS...............................................................................................228 TESTING AND ADJUSTING..........................................................................................................237 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...........................................................................238 MEASURING ENGINE SPEED.....................................................................................................240 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).............................................................................241 MEASURING EXHAUST GAS TEMPERATURE..........................................................................................242 MEASURING EXHAUST GAS COLOR................................................................................................243 ADJUSTING VALVE CLEARANCE..................................................................................................244 MEASURING COMPRESSION PRESSURE.............................................................................................245 MEASURING BLOW-BY PRESSURE.................................................................................................247 MEASURING ENGINE OIL PRESSURE..............................................................................................248 HANDLING EQUIPMENT IN FUEL CIRCUIT.........................................................................................249 RELEASING REMAINING PRESSURE IN FUEL SYSTEM................................................................................249 MEASURING FUEL PRESSURE....................................................................................................250 BLEEDING AIR FROM FUEL CIRCUIT.............................................................................................251 CHECK FOR LEAKAGE IN FUEL SYSTEM...........................................................................................253 ADJUSTING ENGINE SPEED SENSOR..............................................................................................254 TESTING AND ADJUSTING FAN BELT TENSION.....................................................................................255 TESTING AND ADJUSTING ALTERNATOR BELT TENSION..............................................................................256 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION..............................................................257 TESTING CLEARANCE OF SWING CIRCLE BEARING..................................................................................258 TESTING AND ADJUSTING TRACK SHOE TENSION...................................................................................259 TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES..............................................260 TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE.........................................................................265 TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE.....................................................................267 TESTING SERVO PISTON STROKE................................................................................................273 MEASURING PPC VALVE OUTPUT PRESSURE........................................................................................274 MEASURING OUTLET PRESSURES OF SOLENOID VALVE AND PPC SHUTTLE VALVE.........................................................278 ADJUSTING WORK EQUIPMENT・SWING PPC VALVE...................................................................................284 TESTING AND ADJUSTING TRAVEL DEVIATION.....................................................................................285 INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT...............................................................287 MEASURING OIL LEAKAGE .....................................................................................................288 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT..........................................................................292 BLEEDING AIR FROM EACH PART................................................................................................293 INSPECTION PROCEDURES FOR DIODE............................................................................................296 SPECIAL FUNCTION OF MONITOR PANEL..........................................................................................297 HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT............................................................................324 PREPARATION WORK FOR TROUBLESHOOTING ELECTRICAL SYSTEM.....................................................................325 PM-CLINIC SERVICE..........................................................................................................327 UNDERCARRIAGE INSPECTION...................................................................................................333 TROUBLESHOOTING................................................................................................................334 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................................................335 SEQUENCE OF EVENTS IN TROUBLESHOOTING......................................................................................336 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...........................................................................337 CHECKS BEFORE TROUBLESHOOTING..............................................................................................345 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING...............................................................................346 CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM..........................................................350 TROUBLESHOOTING WHEN ERROR CODE (ELECTRICAL SYSTEM) AND FAILURE CODE (MECHANICAL SYSTEM) ARE DISPLAYED (DISPLAYED CODE)....391 BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE..................................................................393 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.........................................................................395 ERROR CODE IN ELECTRICAL SYSTEM E112 (WIPER DRIVE (FOR) S/C)...........................................................397 ERROR CODE IN ELECTRICAL SYSTEM E113 (WIPER DRIVE (REV) S/C)...........................................................401 ERROR CODE IN ELECTRICAL SYSTEM E114 (WASHER DRIVE S/C)................................................................403 ERROR CODE IN ELECTRICAL SYSTEM E115 (WIPER WORKING ABNORMALITY).......................................................405 ERROR CODE IN ELECTRICAL SYSTEM E116 (WIPER PARKING ABNORMALITY).......................................................407 ERROR CODE IN ELECTRICAL SYSTEM E117 (ENG. CONTROLLER S-NET COMM. ERR.)................................................411 ERROR CODE IN ELECTRICAL SYSTEM E118 (PUMP CONTROLLER S-NET COMM. ERR.)................................................413 ERROR CODE IN ELECTRICAL SYSTEM E128 (MONITOR COMM. ABNORMALITY).......................................................415 ERROR CODE IN ELECTRICAL SYSTEM E201 (CO CANCEL SOL. S/C)..............................................................417 ERROR CODE IN ELECTRICAL SYSTEM E203 (SWING BRAKE SOL. S/C)............................................................419 ERROR CODE IN ELECTRICAL SYSTEM E204 (2-STAGE RELIEF SOL. S/C).........................................................421 ERROR CODE IN ELECTRICAL SYSTEM E206 (TRAVEL SPEED SOL. S/C)...........................................................423 ERROR CODE IN ELECTRICAL SYSTEM E207 (FLASH LIGHT RELAY S/C)...........................................................425 ERROR CODE IN ELECTRICAL SYSTEM E211 (CO CANCEL SOL. DISC.)............................................................427 ERROR CODE IN ELECTRICAL SYSTEM E213 (SWING BRAKE SOL. DISC.)..........................................................429 ERROR CODE IN ELECTRICAL SYSTEM E214 (2-STAGE RELIEF SOL. DISC.).......................................................431 ERROR CODE IN ELECTRICAL SYSTEM E216 (TRAVEL SPEED SOL. DISC.).........................................................433 ERROR CODE IN ELECTRICAL SYSTEM E217 (MODEL SELECTION ABNORMALITY).....................................................435 ERROR CODE IN ELECTRICAL SYSTEM E218 (S-NET COMM. DISC.)...............................................................437 ERROR CODE IN ELECTRICAL SYSTEM E221 (TRAVEL ALARM S/C)................................................................439 ERROR CODE IN ELECTRICAL SYSTEM E224 (F PUMP P. SENSOR ABNORMALITY)....................................................441 ERROR CODE IN ELECTRICAL SYSTEM E225 (R PUMP P. SENSOR ABNORMALITY)....................................................443 ERROR CODE IN ELECTRICAL SYSTEM E226 (PRESS. SENSOR POWER ABNORMALITY).................................................445 ERROR CODE IN ELECTRICAL SYSTEM E227 (ENGINE SPEED SENSOR ABNORMALITY).................................................447 ERROR CODE IN ELECTRICAL SYSTEM E232 (TVC SOL. S/C)....................................................................449 ERROR CODE IN ELECTRICAL SYSTEM E233 (TVC SOL. DISC.)..................................................................451 ERROR CODE IN ELECTRICAL SYSTEM E257 (PUMP COMM. ABNORMALITY)..........................................................453 ERROR CODE IN ELECTRICAL SYSTEM E302 (STEP LIGHT RELAY S/C)............................................................455 ERROR CODE IN ELECTRICAL SYSTEM E304 (STEP LIGHT POWER HOLD RELAY S/C).................................................457 ERROR CODE IN ELECTRICAL SYSTEM E311 (BUCKET CURL HI CANCEL SOL. S/C)..................................................459 ERROR CODE IN ELECTRICAL SYSTEM E312 (BUCKET CURL HI CANCEL SOL. DISC.)................................................461 ERROR CODE IN ELECTRICAL SYSTEM E315 (BATTERY RELAY DRIVE S/C).........................................................463 ERROR CODE IN ELECTRICAL SYSTEM E91B (ENGINE NE SENSOR PROBLEM)........................................................465 ERROR CODE IN ELECTRICAL SYSTEM E91C (ENGINE G SENSOR PROBLEM).........................................................466 ERROR CODE IN ELECTRICAL SYSTEM E920 (ENGINE TYPE SELECTION ERROR).....................................................467 ERROR CODE IN ELECTRICAL SYSTEM E921 (ENGINE TYPE MISMATCH)............................................................469 ERROR CODE IN ELECTRICAL SYSTEM E931 (FUEL DIAL SYS. ERROR)............................................................470 ERROR CODE IN ELECTRICAL SYSTEM E934 (ENGINE COOLANT SENSOR HI ERROR)..................................................472 ERROR CODE IN ELECTRICAL SYSTEM E936 (ENGINE OIL PRESS. SW. ERROR).....................................................474 ERROR CODE IN ELECTRICAL SYSTEM E93C (ENGINE BOOST SENSOR ERROR).......................................................476 ERROR CODE IN ELECTRICAL SYSTEM E93D (ENGINE FUEL TEMP. SENSOR ERROR)..................................................478 ERROR CODE IN ELECTRICAL SYSTEM E953 (ENGINE COMM. ABNORMALITY)........................................................480 ERROR CODE IN ELECTRICAL SYSTEM E954 (SHORT ENGINE STARTER SW.)........................................................482 ERROR CODE IN ELECTRICAL SYSTEM E955 (ENGINE S-NET ERROR)..............................................................484 ERROR CODE IN ELECTRICAL SYSTEM E956 (ENGINE POWER FAILURE (1))........................................................486 ERROR CODE IN ELECTRICAL SYSTEM E957 (ENGINE POWER FAILURE (2))........................................................488 ERROR CODE IN ELECTRICAL SYSTEM E95A (ENGINE Q-ADJ. SW. SIGNAL ERROR)..................................................490 ERROR CODE IN ELECTRICAL SYSTEM E96A (ENGINE COOLANT SENSOR LO ERROR)..................................................491 ERROR CODE IN ELECTRICAL SYSTEM E970 (PCV1 OVER CURRENT)...............................................................493 ERROR CODE IN ELECTRICAL SYSTEM E971 (PCV2 OVER CURRENT)...............................................................495 ERROR CODE IN ELECTRICAL SYSTEM E974 (PCV1 LINE CUT)...................................................................497 ERROR CODE IN ELECTRICAL SYSTEM E975 (PCV2 LINE CUT)...................................................................499 ERROR CODE IN ELECTRICAL SYSTEM E977 (RAIL PRESS. SENSOR ERROR)........................................................501 ERROR CODE IN ELECTRICAL SYSTEM E979 (RAIL PRESS. HIGH)................................................................503 ERROR CODE IN ELECTRICAL SYSTEM E97A (RAIL PRESS. ABNORMAL)............................................................503 ERROR CODE IN ELECTRICAL SYSTEM E97B (RAIL PRESS. LOW).................................................................504 ERROR CODE IN ELECTRICAL SYSTEM E97C (RAIL PRESS. TOO LOW).............................................................506 ERROR CODE IN ELECTRICAL SYSTEM E97D (RAIL PRESS. OUT OF CONTROL)......................................................506 ERROR CODE IN ELECTRICAL SYSTEM E980 (ENG. CONTROLLER ABNORMALITY).....................................................507 ERROR CODE IN ELECTRICAL SYSTEM E981 (FUEL INJECTOR 1 DISC.)...........................................................509 ERROR CODE IN ELECTRICAL SYSTEM E982 (FUEL INJECTOR 2 DISC.)...........................................................510 ERROR CODE IN ELECTRICAL SYSTEM E983 (FUEL INJECTOR 3 DISC.)...........................................................511 ERROR CODE IN ELECTRICAL SYSTEM E984 (FUEL INJECTOR 4 DISC.)...........................................................512 ERROR CODE IN ELECTRICAL SYSTEM E985 (FUEL INJECTOR 5 DISC.)...........................................................513 ERROR CODE IN ELECTRICAL SYSTEM E986 (FUEL INJECTOR 6 DISC.)...........................................................514 ERROR CODE IN ELECTRICAL SYSTEM E98A (FUEL INJECTOR 1-3 S/C)...........................................................515 ERROR CODE IN ELECTRICAL SYSTEM E98B (FUEL INJECTOR 4-6 S/C)...........................................................517 FAILURE CODE IN MECHANICAL SYSTEM A000N1 (ENG. HI OUT OF STD)..........................................................519 FAILURE CODE IN MECHANICAL SYSTEM AA10NX (AIRCLEANER CLOGGING).........................................................520 FAILURE CODE IN MECHANICAL SYSTEM AB00KE (CHARGE VOLTAGE LOW)..........................................................522 FAILURE CODE IN MECHANICAL SYSTEM B@BAZG (ENG. OIL PRESS. LOW).........................................................524 FAILURE CODE IN MECHANICAL SYSTEM B@BAZK (ENG. OIL LEVEL LOW)..........................................................526 FAILURE CODE IN MECHANICAL SYSTEM B@BCNS (ENG. WATER OVERHEAT).........................................................527 FAILURE CODE IN MECHANICAL SYSTEM B@BCZK (ENG. WATER LVL LOW)..........................................................528 FAILURE CODE IN MECHANICAL SYSTEM B@HANS (HYDR. OIL OVERHEAT)..........................................................530 FAILURE CODE IN MECHANICAL SYSTEM DA80MA (AUTO. LUB ABNORMAL)..........................................................532 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..............................................................................533 BEFORE CARRYING OUT TROUBLESHOOTING E MODE.............................................................................534 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.........................................................................536 E-1 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE).....................................................................537 E-2 PREHEATER DOES NOT OPERATE.........................................................................................540 E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK...........................................................................542 E-4 AUTO-DECELERATOR DOES NOT OPERATE..................................................................................543 E-5 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE...................................................................544 E-6 ONE-TOUCH POWER MAX, FUNCTION DOES NOT OPERATE.....................................................................546 E-7 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY.................................................................547 E-8 ANY ITEM IS NOT DISPLAYED ON MONITOR PANEL.........................................................................549 E-9 PART OF DISPLAY ON MONITOR PANEL IS MISSING........................................................................550 E-10 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL...........................................................550 E-11 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING.....................................................551 E-12 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.........................................................552 E-13 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY........................................................554 E-14 FUEL GAUGE DOES NOT DISPLAY CORRECTLY.............................................................................555 E-15 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY.....................................................................556 E-16 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED.............................................................558 E-17 WIPER AND WINDOW WASHER DO NOT WORK...............................................................................560 E-18 ALARM BUZZER CANNOT BE CANCELLED..................................................................................567 E-19 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................................568 E-20 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................................569 E-21 "ARM CURL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION......................................................570 E-22 "ARM DUMP" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION......................................................571 E-23 "BUCKET CURL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION...................................................572 E-24 "BUCKET DUMP" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION...................................................573 E-25 "SWING" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION.........................................................574 E-26 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION........................................................576 E-27 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION.......................................................578 E-28 AIR CONDITIONER DOES NOT WORK.....................................................................................580 E-29 STEP LIGHT DOES NOT LIGHT UP OR GO OFF............................................................................581 E-30 ELECTRIC GREASE GUN DOES NOT OPERATE..............................................................................585 E-31 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING.............................................................587 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)................................................................589 BEFORE TROUBLESHOOTING H MODE..........................................................................................590 INFORMATION IN TROUBLESHOOTING TABLE...................................................................................595 H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, TRAVEL, AND SWING IS LOW.....................................................596 H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS....................................................................598 H-3 ALL WORK EQUIPMENT, TRAVEL, AND SWING SYSTEMS DO NOT WORK..........................................................599 H-4 ABNORMAL SOUND IS HEARD FROM AROUND PUMP...........................................................................600 H-5 AUTO-DECELERATOR IS NOT RESET......................................................................................601 H-6 BOOM SPEED OR POWER IS LOW.........................................................................................602 H-7 ARM SPEED OR POWER IS LOW..........................................................................................604 H-8 BUCKET SPEED OR POWER IS LOW.......................................................................................605 H-9 BOOM DOES NOT MOVE.................................................................................................606 H-10 ARM DOES NOT MOVE.................................................................................................606 H-11 BUCKET DOES NOT MOVE..............................................................................................606 H-12 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE........................................................................607 H-13 TIME LAG OF WORK EQUIPMENT IS LARGE...............................................................................609 H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT OPERATE OR STOP............................................................610 H-15 HEAVY LIFT FUNCTION DOES NOT OPERATE OR STOP......................................................................610 H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE OR STOP.................................................................610 H-17 WHEN ARM AND BOOM・BUCKET ARE OPERATED SIMULTANEOUSLY, BOOM・BUCKET SPEED IS LOW....................................611 H-18 WHEN BUCKET AND BOOM・ARM・SWING・TRAVEL ARE OPERATED SIMULTANEOUSLY, BOOM・ARM・SWING・TRAVEL SPEED IS LOW.............611 H-19 WHEN ARM AND SWING ARE OPERATED SIMULTANEOUSLY, SWING SPEED IS LOW................................................612 H-20 MACHINE DEVIATES IN ONE DIRECTION.................................................................................613 H-21 MACHINE DEVIATES LARGELY AT START.................................................................................615 H-22 TRAVEL DEVIATION IS LARGE DURING COMPOUND OPERATION...............................................................616 H-23 TRAVEL SPEED OR POWER IS LOW......................................................................................617 H-24 MACHINE DOES NOT TRAVEL (ONLY ONE TRACK)..........................................................................618 H-25 TRAVEL SPEED DOES NOT CHANGE......................................................................................619 H-26 UPPER STRUCTURE DOES NOT SWING....................................................................................620 H-27 SWING SPEED OR ACCELERATION IS LOW................................................................................621 H-28 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING.......................................................622 H-29 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING ..........................................................623 H-30 LARGE ABNORMAL SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING..................................................624 H-31 HYDRAULIC DRIFT OF SWING IS LARGE.................................................................................625 TROUBLESHOOTING OF ENGINE (S MODE).........................................................................................626 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................627 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................628 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..........................................................631 S-2 ENGINE DOES NOT START..............................................................................................632 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...............................................................635 S-4 ENGINE STOPS DURING OPERATIONS.....................................................................................636 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)..........................................................................637 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...............................................................................638 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).....................................................................639 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)............................................................640 S-9 OIL BECOMES CONTAMINATED QUICKLY...................................................................................641 S-10 FUEL CONSUMPTION IS EXCESSIVE.....................................................................................642 S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)..........................................643 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)........................................................644 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)..............................................................................645 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..................................................................646 S-15 ABNORMAL NOISE IS MADE............................................................................................647 S-16 VIBRATION IS EXCESSIVE............................................................................................648 30 DISASSEMBLY AND ASSEMBLY........................................................................................................649 METHOD OF USING MANUAL.........................................................................................................651 PRECAUTIONS WHEN CARRYING OUT OPERATION........................................................................................653 SPECIAL TOOL LIST..............................................................................................................655 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY..........................................................................672 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY.............................................................................675 REMOVAL AND INSTALLATION OF NOZZLE TIP.........................................................................................679 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL..................................................................................681 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL...................................................................................683 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.............................................................................688 REMOVAL AND INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY................................................................694 REMOVAL AND INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY...............................................................696 REMOVAL AND INSTALLATION OF PTO ASSEMBLY.......................................................................................699 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY.......................................................................................700 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY.................................................................................702 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY...............................................................................703 DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR ASSEMBLY..............................................................................715 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY...........................................................................730 REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY...............................................................................731 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR ASSEMBLY...............................................................................732 REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY...........................................................................743 DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY...........................................................................744 REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY..............................................................................752 REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY................................................................................753 DISASSEMBLY AND ASSEMBLY OF ONE LINK IN FIELD..................................................................................755 REMOVAL AND INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY......................................................................758 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY.....................................................................................759 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY.............................................................................762 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY..............................................................................764 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY..............................................................................765 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY............................................................................768 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY............................................................................769 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY............................................................................772 DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY.........................................................................774 REMOVAL AND INSTALLATION OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY........................................................776 DISASSEMBLY AND ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY........................................................................778 REMOVAL AND INSTALLATION OF NO.1 AND NO.2 PUMP ASSEMBLY........................................................................782 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY............................................................................784 REMOVAL AND INSTALLATION OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY.............................................................804 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY.......................................................................805 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY.......................................................................806 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................807 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY..........................................................................809 REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY...........................................................................811 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY..............................................................................813 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY.............................................................................815 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY........................................................................817 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY....................................................................................822 REMOVAL AND INSTALLATION OF ARM ASSEMBLY.......................................................................................824 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY......................................................................................826 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY............................................................................829 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY.............................................................................830 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS).................................................................831 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY..............................................................................840 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY.............................................................................846 90 OTHERS..........................................................................................................................847 HYDRAULIC CIRCUIT DIAGRAM......................................................................................................848 ELECTRICAL CIRCUIT DIAGRAM (1/5)...............................................................................................849 ELECTRICAL CIRCUIT DIAGRAM (2/5)...............................................................................................850 ELECTRICAL CIRCUIT DIAGRAM (3/5)...............................................................................................851 ELECTRICAL CIRCUIT DIAGRAM (4/5)...............................................................................................852 ELECTRICAL CIRCUIT DIAGRAM (5/5)...............................................................................................853 ELECTRICAL CIRCUIT FOR AIR CONDITIONER.........................................................................................854
Description:
Komatsu PC600-7 PC600LC-7 Service Repair Manual
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
- STRUCTURE AND FUNCTION
This 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.Troubleshooting charts correlating “Problems” with “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. - MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
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