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Komatsu PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0 PC700LC-8E0 Excavator Shop Manual SEN05377-03 – PDF DOWNLOAD
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Komatsu PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0 PC700LC-8E0 Excavator Shop Manual
SERIAL NUMBERS : 65001 and up
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Description
Komatsu PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0 PC700LC-8E0 Excavator Shop Manual
FILE DETAILS:
Komatsu PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0 PC700LC-8E0 Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0
Serial Number: 65001 and up
Book Code: SEN05377-03
Language: English
Pages: 1379
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0 PC700LC-8E0 Excavator Shop Manual
How to read the shop manual:
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 contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
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 tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
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.
60. Maintenance standard
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0 PC700LC-8E0 Excavator Shop Manual
COVER ...................................................................................................................... 1 00 Index and foreword....................................................................................................... 11 Table of Contents....................................................................................................... 12 Table of Contents................................................................................................... 12 Foreword and general information........................................................................................ 22 Safety notice....................................................................................................... 22 How to read the shop manual......................................................................................... 27 Explanation of terms for maintenance standard....................................................................... 29 Handling of hydraulic components.................................................................................... 31 Method of disconnecting and connecting push-pull type coupler....................................................... 33 Handling of electric equipment...................................................................................... 36 How to read electric wire code...................................................................................... 46 Precautions when performing work.................................................................................... 49 Standard tightening torque table.................................................................................... 52 List of abbreviation................................................................................................ 56 Conversion table.................................................................................................... 60 01 Specification............................................................................................................ 65 Specifications.......................................................................................................... 68 Specifications drawing.............................................................................................. 68 Working range drawings.............................................................................................. 70 Specifications...................................................................................................... 72 Table of weight..................................................................................................... 82 Table of fuel, coolant and lubricants............................................................................... 90 10 Structure and function................................................................................................... 93 Engine and cooling system............................................................................................... 95 Engine related parts................................................................................................ 95 PTO................................................................................................................. 96 Cooling system...................................................................................................... 97 Power train system...................................................................................................... 98 Power train......................................................................................................... 98 Swing circle........................................................................................................ 100 Swing machinery..................................................................................................... 102 Final drive......................................................................................................... 104 Undercarriage and frame................................................................................................. 106 Track frame and idler cushion....................................................................................... 106 Hydraulic system........................................................................................................ 108 Hydraulic component layout.......................................................................................... 108 Valve control....................................................................................................... 110 Hydraulic tank and filter........................................................................................... 112 Hydraulic pump (piston pump)........................................................................................ 114 Cooling fan pump.................................................................................................... 142 Cooling fan motor................................................................................................... 150 Control valve....................................................................................................... 156 Swing motor......................................................................................................... 172 Travel motor........................................................................................................ 180 PPC valve........................................................................................................... 201 Solenoid valve...................................................................................................... 209 PPC shuttle valve................................................................................................... 216 Boom drift prevention valve......................................................................................... 217 Boom LOWER regeneration valve....................................................................................... 221 Arm regeneration valve.............................................................................................. 224 Quick return valve.................................................................................................. 227 Line oil filter..................................................................................................... 230 Center swivel joint................................................................................................. 231 Accumulator......................................................................................................... 232 Electrical system....................................................................................................... 233 Engine control...................................................................................................... 233 Electrical control system........................................................................................... 243 Monitor system...................................................................................................... 273 KOMTRAX system...................................................................................................... 299 Sensors............................................................................................................. 301 20 Standard value table..................................................................................................... 305 Standard value table.................................................................................................... 307 Standard value table for engine..................................................................................... 307 Standard value table for machine.................................................................................... 308 30 Testing and adjusting.................................................................................................... 331 Tool for testing, adjusting and troubleshooting......................................................................... 333 Tools for testing, adjusting, and troubleshooting................................................................... 333 Engine and cooling system............................................................................................... 337 Testing engine speed................................................................................................ 337 Testing intake air pressure (boost pressure)........................................................................ 339 Testing exhaust gas temperature..................................................................................... 340 Testing exhaust gas color........................................................................................... 341 Testing and adjusting valve clearance............................................................................... 342 Testing compression pressure........................................................................................ 343 Testing blowby pressure............................................................................................. 345 Testing engine oil pressure......................................................................................... 346 Testing EGR valve and bypass valve drive pressure................................................................... 347 Handling fuel system parts.......................................................................................... 348 Releasing remaining pressure from fuel system....................................................................... 349 Testing fuel pressure............................................................................................... 350 Cylinder cut-out test mode.......................................................................................... 351 No-injection cranking............................................................................................... 352 Testing fuel return rate and leakage................................................................................ 353 Bleeding air from fuel circuit...................................................................................... 356 Testing fuel circuit for leakage.................................................................................... 358 Testing and adjusting alternator belt tension....................................................................... 359 Testing and adjusting air conditioner compressor belt tension....................................................... 360 Undercarriage and frame................................................................................................. 361 Testing swing circle bearing clearance.............................................................................. 361 Checking and adjusting track tension................................................................................ 362 Hydraulic system........................................................................................................ 363 Testing and adjusting oil pressure in work equipment, swing and travel circuits..................................... 363 Testing and adjusting control circuit oil pressure.................................................................. 368 Testing and adjusting control oil pressure of piston pump........................................................... 370 Testing servo piston movement....................................................................................... 376 Testing PPC valve output pressure................................................................................... 378 Testing output pressure of solenoid valve and PPC shuttle valve..................................................... 382 Adjusting play of work equipment and swing PPC vavles............................................................... 388 Isolating the parts causing hydraulic drift in work equipment....................................................... 389 Testing and adjusting travel deviation.............................................................................. 391 Testing fan speed................................................................................................... 393 Testing fan circuit oil pressure.................................................................................... 394 Releasing remaining pressure from hydraulic circuit................................................................. 395 Testing oil leakage................................................................................................. 396 Bleeding air from each part......................................................................................... 400 Electrical system....................................................................................................... 403 Special functions of machine monitor................................................................................ 403 Handling of voltage circuit of engine controller.................................................................... 447 Preparatory work for troubleshooting of electrical system........................................................... 448 Inspection procedure of diode....................................................................................... 453 Pm clinic............................................................................................................... 454 Pm Clinic service................................................................................................... 454 UNDERCARRIAGE INSPECTION REPORT..................................................................................... 466 40 Troubleshooting.......................................................................................................... 469 General information on troubleshooting.................................................................................. 476 Points to remember when troubleshooting............................................................................. 476 Sequence of events in troubleshooting............................................................................... 477 Checks before troubleshooting....................................................................................... 478 Classification and procedures for troubleshooting................................................................... 502 Failure codes table................................................................................................. 505 Symptom and troubleshooting numbers................................................................................. 509 Information in troubleshooting table................................................................................ 512 Troubleshooting method for open circuit in wiring harness of pressure sensor system................................. 514 Connector list and layout........................................................................................... 516 Connection table for connector pin numbers.......................................................................... 526 T- branch box and T- branch adapter table........................................................................... 562 Fuse locations...................................................................................................... 565 Troubleshooting by failure code......................................................................................... 568 Failure code [989L00] Engine Controller Lock Caution 1.............................................................. 568 Failure code [989M00] Engine Controller Lock Caution 2.............................................................. 569 Failure code [989N00] Engine Controller Lock Caution 3.............................................................. 570 Failure code [AA10NX] Air Cleaner Clogging.......................................................................... 571 Failure code [AB00KE] Charge Voltage Low............................................................................ 572 Failure code [B@BAZG] Eng Oil Press Low............................................................................. 574 Failure code [B@BAZK] Eng Oil Level Low............................................................................. 575 Failure code [B@BCNS] Eng Water Overheat............................................................................ 576 Failure code [B@BCZK] Eng Water Level Low........................................................................... 578 Failure code [B@HANS] Hyd Oil Overheat.............................................................................. 580 Failure code [CA111] ECM Critical Internal Failure.................................................................. 582 Failure code [CA115] Eng Ne and Bkup Speed Sens Error............................................................... 584 Failure code [CA122] Chg Air Press Sensor High Error................................................................ 586 Failure code [CA123] Chg Air Press Sensor Low Error................................................................. 588 Failure code [CA131] Throttle Sensor High Error..................................................................... 590 Failure code [CA132] Throttle Sensor Low Error...................................................................... 592 Failure code [CA135] Eng Oil Press Sensor High Error................................................................ 594 Failure code [CA141] Eng Oil Press Sensor Low Error................................................................. 596 Failure code [CA144] Coolant Temp Sens High Error................................................................... 598 Failure code [CA145] Coolant Temp Sens Low Error.................................................................... 600 Failure code [CA153] Chg Air Temp Sensor High Error................................................................. 602 Failure code [CA154] Chg Air Temp Sensor Low Error.................................................................. 604 Failure code [CA187] Sens Supply 2 Volt Low Error................................................................... 606 Failure code [CA221] Ambient Press Sens High Error.................................................................. 608 Failure code [CA222] Ambient Press Sens Low Error................................................................... 610 Failure code [CA227] Sens Supply 2 Volt High Error.................................................................. 612 Failure code [CA234] Eng Overspeed.................................................................................. 613 Failure code [CA238] Ne Speed Sens Supply Volt Error................................................................ 614 Failure code [CA263] Fuel Temp Sensor High Error.................................................................... 616 Failure code [CA265] Fuel Temp Sensor Low Error..................................................................... 618 Failure code [CA271] IMV/PCV1 Short Error........................................................................... 620 Failure code [CA272] IMV/PCV1 Open Error............................................................................ 621 Failure code [CA273] PCV2 Short Error............................................................................... 622 Failure code [CA274] PCV2 Open Error................................................................................ 623 Failure code [CA322] Inj #1(L#1) Open/Short Error................................................................... 624 Failure code [CA323] Inj #5 (L#5) Open/Short Error.................................................................. 626 Failure code [CA324] Inj #3(L#3) Open/Short Error................................................................... 628 Failure code [CA325] Inj #6 (L#6) Open/Short Error.................................................................. 630 Failure code [CA331] Inj #2(L#2) Open/Short Error................................................................... 632 Failure code [CA332] Inj #4 (L#4) Open/Short Error.................................................................. 634 Failure code [CA342] Calibration Code Incompatibility............................................................... 636 Failure code [CA351] Injectors Drive Circuit Error.................................................................. 637 Failure code [CA352] Sens Supply 1 Volt Low Error................................................................... 638 Failure code [CA386] Sens Supply 1 Volt High Error.................................................................. 640 Failure code [CA441] Battery Voltage Low Error...................................................................... 640 Failure code [CA442] Battery Voltage High Error..................................................................... 641 Failure code [CA449] Rail Press Very High Error..................................................................... 641 Failure code [CA451] Rail Press Sensor High Error................................................................... 642 Failure code [CA452] Rail Press Sensor Low Error.................................................................... 644 Failure code [CA553] Rail Press High Error.......................................................................... 646 Failure code [CA554] Rail Press Sensor In Range Error............................................................... 646 Failure code [CA559] Supply Pump Press Low Error 1.................................................................. 647 Failure code [CA689] Eng Ne Speed Sensor Error...................................................................... 650 Failure code [CA731] Eng Bkup Speed Sens Phase Error................................................................ 652 Failure code [CA757] All Continuous Data Lost Error................................................................. 653 Failure code [CA778] Eng Bkup Speed Sensor Error.................................................................... 654 Failure code [CA1228] EGR Valve Servo Error 1....................................................................... 656 Failure code [CA1625] EGR Valve Servo Error 2....................................................................... 657 Failure code [CA1626] BP Valve Sol Current High Error............................................................... 658 Failure code [CA1627] BP Valve Sol Current Low Error................................................................ 660 Failure code [CA1628] Bypass Valve Servo Error 1.................................................................... 662 Failure code [CA1629] Bypass Valve Servo Error 2.................................................................... 663 Failure code [CA1631] BP Valve Pos Sens High Error.................................................................. 664 Failure code [CA1632] BP Valve Pos Sens Low Error................................................................... 666 Failure code [CA1633] KOMNET Datalink Timeout Error................................................................. 668 Failure code [CA2185] Throt Sens Sup Volt High Error................................................................ 670 Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................. 672 Failure code [CA2249] Rail Press Very Low Error..................................................................... 673 Failure code [CA2271] EGR Valve Pos Sens High Error................................................................. 674 Failure code [CA2272] EGR Valve Pos Sens Low Error.................................................................. 676 Failure code [CA2351] EGR Valve Sol Current High Error.............................................................. 678 Failure code [CA2352] EGR Valve Sol Current Low Error............................................................... 680 Failure code [CA2555] Grid Htr Relay Open Circuit Error............................................................. 682 Failure code [CA2556] Grid Htr Relay Short Circuit Error............................................................ 684 Failure code [D110KB] Battery Relay Drive Short Circuit............................................................. 686 Failure code [D163KB] Flash Light Relay Short Circuit............................................................... 688 Failure code [D195KA] Step Light Relay Open Circuit................................................................. 690 Failure code [D195KB] Step Light Relay Short Circuit................................................................ 692 Failure code [D19JKZ] Personal code relay abnormality............................................................... 694 Failure code [D862KA] GPS Antenna Open Circuit...................................................................... 696 Failure code [DA22KK] Pump Solenoid Power Low Error................................................................. 698 Failure code [DA25KP] 5V Sensor1 Power Abnormality.................................................................. 700 Failure code [DA29KQ] Model Selection Abnormality................................................................... 702 Failure code [DA2RMC] CAN Discon (Pump Con Detected)................................................................ 704 Failure code [DA80MA] Auto. Lub. Abnormal........................................................................... 708 Failure code [DAF8KB] Camera Power Supply Short Circuit............................................................. 710 Failure code [DAFGMC] GPS Module Error.............................................................................. 712 Failure code [DAFRMC] CAN Discon (Monitor Detected)................................................................. 713 Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit............................................................... 718 Failure code [DGH2KB] Hyd Oil Sensor Short.......................................................................... 720 Failure code [DHPAMA] F Pump Press Sensor Abnormality............................................................... 722 Failure code [DHPBMA] R Pump Press Sensor Abnormality............................................................... 724 Failure code [DV20KB] Travel alarm short circuit.................................................................... 726 Failure code [DW43KA] Travel Speed Sol Open Circuit................................................................. 728 Failure code [DW43KB] Travel Speed Sol Short Circuit................................................................ 730 Failure code [DW45KA] Swing Brake Sol Open Circuit.................................................................. 732 Failure code [DW45KB] Swing Brake Sol Short Circuit................................................................. 734 Failure code [DW48KA] CO Cancel Sol Open Circuit.................................................................... 736 Failure code [DW48KB] CO Cancel Sol Short Circuit................................................................... 738 Failure code [DW4XKA] Bucket Curl Hi Cancel Sol Open Circuit........................................................ 740 Failure code [DW4XKB] Bucket Curl Hi Cancel Sol Short Circuit....................................................... 742 Failure code [DW7BKA] Fan Reverse Sol Open Circuit.................................................................. 744 Failure code [DW7BKB] Fan Reverse Sol Short Circuit................................................................. 746 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit............................................................... 748 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit.............................................................. 750 Failure code [DX16KA] Fan Pump EPC Sol Open Circuit................................................................. 752 Failure code [DX16KB] Fan Pump EPC Sol Short Circuit................................................................ 753 Failure code [DXA0KA] TVC Sol Open Circuit.......................................................................... 754 Failure code [DXA0KB] TVC Sol Short Circuit......................................................................... 756 Failure code [DY20KA] Wiper Working Abnormality..................................................................... 758 Failure code [DY20MA] Wiper Parking Abnormality..................................................................... 762 Failure code [DY2CKA] Washer Drive Open Circuit..................................................................... 764 Failure code [DY2CKB] Washer Drive Short Circuit.................................................................... 766 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit............................................................... 768 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit............................................................... 772 Failure code [DY2FMA] Upper Wiper Working Abnormality............................................................... 776 Failure code [DY2GKM] Wiper Select Abnormality...................................................................... 778 Troubleshooting of electrical system (E-mode)........................................................................... 782 E-1 Engine does not start (Engine does not crank)................................................................... 782 E-2 Preheater does not operate...................................................................................... 787 E-3 When starting switch is turned to ON position, machine monitor displays nothing................................. 791 E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up........... 794 E-5 Precaution item lights up while engine is running............................................................... 796 E-6 Emergency stop item lights up while engine is running........................................................... 798 E-7 Engine coolant temperature gauge does not indicate properly..................................................... 799 E-8 Fuel gauge does not indicate properly........................................................................... 800 E-9 Hydraulic oil temperature gauge does not indicate properly...................................................... 802 E-10 Content of display on machine monitor is different from that of actual machine................................. 804 E-11 Some areas of machine monitor screen are not displayed......................................................... 804 E-12 Function switch does not operate............................................................................... 804 E-13 Automatic warm-up system does not operate (in cold season)..................................................... 805 E-14 Auto-decelerator does not operate properly..................................................................... 806 E-15 Working mode does not change................................................................................... 807 E-16 Travel speed does not change................................................................................... 808 E-17 Alarm buzzer cannot be canceled................................................................................ 809 E-18 When starting switch is turned OFF, service meter is not displayed............................................. 809 E-19 Service mode cannot be selected................................................................................ 809 E-20 Any of work equipment, swing and travel does not work or cannot be locked...................................... 810 E-21 Machine push-up function does not work or cannot be canceled................................................... 812 E-22 Boom shockless function does not operate normally.............................................................. 814 E-23 Swing brake does not operate normally.......................................................................... 816 E-24 Windshield wiper and window washer do not operate.............................................................. 818 E-25 Travel alarm does not sound or does not stop sounding.......................................................... 821 E-26 BOOM RAISE indicator is not displayed properly with monitoring function........................................ 822 E-27 BOOM LOWER indicator is not displayed properly with monitoring function........................................ 824 E-28 ARM IN indicator is not displayed properly with monitoring function............................................ 826 E-29 ARM DUMP indicator is not displayed properly with monitoring function.......................................... 828 E-30 BUCKET CURL indicator is not displayed properly with monitoring function....................................... 830 E-31 BUCKET DUMP indicator is not displayed properly with monitoring function....................................... 832 E-32 Swing indicator is not displayed properly with monitoring function............................................. 834 E-33 Travel indicator is not displayed properly with monitoring function............................................ 836 E-34 "Service" is not displayed normally by monitoring function..................................................... 838 E-35 Electric grease gun does not operate........................................................................... 840 E-36 KOMTRAX system does not operate normally....................................................................... 841 E-37 Bottom dump does not operate properly.......................................................................... 842 E-38 Horn does not sound or does not stop sounding.................................................................. 845 E-39 Step light does not light up or go off......................................................................... 848 Troubleshooting of hydraulic and mechanical system (H-mode)............................................................. 852 Before troubleshooting for hydraulic and mechanical systems......................................................... 852 Information in troubleshooting table (H-mode)....................................................................... 857 H-1 All of work equipment, travel and swing work slow or lack power................................................. 858 H-2 Engine speed lowers significantly or engine stalls.............................................................. 860 H-3 Any of work equipment, swing and travel does not work........................................................... 862 H-4 Unusual noise is heard from around hydraulic pump............................................................... 864 H-5 Auto-decelerator is not canceled................................................................................ 865 H-6 Speed or power of boom is low................................................................................... 866 H-7 Speed or power of arm is low.................................................................................... 868 H-8 Speed or power of bucket is low................................................................................. 869 H-9 Boom does not move.............................................................................................. 870 H-10 Arm does not move.............................................................................................. 870 H-11 Bucket does not move........................................................................................... 871 H-12 Bottom dump does not move...................................................................................... 871 H-13 Hydraulic drift of work equipment is large..................................................................... 872 H-14 Time lag of work equipment is large............................................................................ 873 H-15 One-touch power maximizing function does not work or is not canceled........................................... 874 H-16 Machine push-up function does not work or is not canceled...................................................... 874 H-17 Boom/bucket speed is low at combined operation of arm and boom or bucket....................................... 874 H-18 Speed of boom, arm, swing and travel is low at combined operation of bucket and boom, arm, swing and travel.... 875 H-19 Swing speed is low at combined operation of arm and swing...................................................... 875 H-20 Machine deviates during travel................................................................................. 876 H-21 Machine deviates significantly at start........................................................................ 879 H-22 Machine deviates significantly during combined operation....................................................... 880 H-23 Travel speed or travel power is low............................................................................ 881 H-24 One of tracks does not run (on one side alone)................................................................. 882 H-25 Travel speed does not change................................................................................... 883 H-26 Upper structure does not swing................................................................................. 884 H-27 Swing speed is low or acceleration is poor..................................................................... 885 H-28 Upper structure overruns excessively when it stops swinging.................................................... 886 H-29 Shock is large when upper structure stops swinging............................................................. 887 H-30 Large unusual noise is heard when upper structure stops swinging40............................................. 888 H-31 Hydraulic drift of swing is large.............................................................................. 889 Troubleshooting of engine (S-mode)...................................................................................... 890 Method of using troubleshooting chart............................................................................... 890 S-1 Startability is poor............................................................................................ 894 S-2 Engine does not start........................................................................................... 896 S-3 Engine does not pick up smoothly................................................................................ 900 S-4 Engine stops during operation................................................................................... 901 S-5 Engine runs rough or is unstable................................................................................ 902 S-6 Engine lacks power.............................................................................................. 904 S-7 Exhaust smoke is black (incomplete combustion).................................................................. 906 S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................................... 908 S-9 Oil becomes contaminated early.................................................................................. 909 S-10 Fuel consumption is excessive.................................................................................. 910 S-11 Oil is in coolant (or coolant spurts or coolant level goes down)............................................... 911 S-12 Oil pressure drops............................................................................................. 912 S-13 Oil level rises (coolant or fuel in oil)....................................................................... 914 S-14 Coolant temperature rises too high (overheating)............................................................... 916 S-15 Unusual noise is made.......................................................................................... 917 S-16 Vibration is excessive......................................................................................... 918 50 Disassembly and assembly................................................................................................. 919 General information on disassembly and assembly......................................................................... 922 How to read Disassembly and Assembly................................................................................ 922 Coating materials list.............................................................................................. 924 Special tools list.................................................................................................. 927 Sketches of special tools........................................................................................... 934 Engine and cooling system............................................................................................... 942 Removal and installation of fuel supply pump assembly............................................................... 942 Removal and installation of fuel injector assembly.................................................................. 948 Removal and installation of cylinder head assembly.................................................................. 951 Removal and installation of radiator assembly....................................................................... 968 Removal and installation of hydraulic oil cooler assembly........................................................... 970 Removal and installation of aftercooler assembly.................................................................... 972 Removal and installation of engine front seal....................................................................... 974 Removal and installation of engine rear seal........................................................................ 978 Removal and installation of engine, PTO and hydraulic pump assembly................................................. 983 Removal and installation of cooling fan motor assembly.............................................................. 991 Removal and installation of fuel tank assembly...................................................................... 995 Power train............................................................................................................. 996 Removal and installation of PTO assembly............................................................................ 996 Disassembly and assembly of PTO assembly............................................................................ 998 Disassembly and assembly of final drive assembly....................................................................1001 Removal and installation of swing motor and swing machinery assembly50..............................................1024 Disassembly and assembly of swing machinery assembly................................................................1026 Removal and installation of swing circle assembly...................................................................1041 Undercarriage and frame.................................................................................................1042 Separation and connection of track shoe assembly....................................................................1042 Disassembly and assembly of one link in field.......................................................................1046 Removal and installation of idler assembly..........................................................................1050 Disassembly and assembly of idler assembly..........................................................................1052 Removal and installation of idler cushion assembly..................................................................1059 Disassembly and assembly of idler cushion assembly..................................................................1062 Removal and installation of track roller assembly...................................................................1066 Disassembly and assembly of track roller assembly...................................................................1068 Removal and installation of carrier roller assembly.................................................................1074 Disassembly and assembly of carrier roller assembly.................................................................1076 Removal and installation of revolving frame assembly................................................................1082 Removal and installation of counterweight assembly..................................................................1084 Removal and installation of counterweight remover assembly..........................................................1087 Hydraulic system........................................................................................................1089 Removal and installation of center swivel joint assembly............................................................1089 Disassembly and assembly of center swivel joint assembly............................................................1090 Removal and installation of hydraulic tank assembly.................................................................1092 Removal and installation of hydraulic pump assembly.................................................................1094 Removal and installation of control valve assembly..................................................................1097 Disassembly and assembly of control valve assembly..................................................................1099 Removal and installation of swing motor assembly....................................................................1101 Disassembly and assembly of work equipment PPC valve assembly.......................................................1102 Disassembly and assembly of travel PPC valve assembly...............................................................1104 Disassembly and assembly of grease gun assembly.....................................................................1106 Work equipment..........................................................................................................1107 Removal and installation of bucket cylinder assembly................................................................1107 Removal and installation of arm cylinder assembly...................................................................1111 Removal and installation of boom cylinder assembly..................................................................1115 Removal and installation of bottom dump cylinder assembly...........................................................1119 Removal and installation of bucket assembly.........................................................................1121 Removal and installation of arm assembly............................................................................1125 Removal and installation of boom assembly...........................................................................1128 Removal and installation of work equipment assembly.................................................................1132 Disassembly and assembly of work equipment cylinder assembly........................................................1136 Cab and its attachments.................................................................................................1142 Removal and installation of operator's cab assembly.................................................................1142 Removal and installation of operator's cab glass (adhered window glass).............................................1146 Removal and installation of front window assembly...................................................................1156 Removal and installation of air conditioner unit assembly...........................................................1163 Electrical system.......................................................................................................1167 Removal and installation of air conditioner compressor assembly.....................................................1167 Removal and installation of air conditioner condenser assembly......................................................1170 Removal and installation of engine controller assembly..............................................................1172 Removal and installation of pump controller assembly................................................................1174 Removal and installation of KOMTRAX terminal assembly...............................................................1176 Removal and installation of machine monitor assembly................................................................1177 60 Maintenance standard.....................................................................................................1179 Engine and cooling system...............................................................................................1181 Engine mount........................................................................................................1181 PTO.................................................................................................................1183 Cooling system......................................................................................................1184 Power train.............................................................................................................1185 Swing circle........................................................................................................1185 Swing machinery.....................................................................................................1186 Final drive.........................................................................................................1188 Sprocket............................................................................................................1190 Undercarriage and frame.................................................................................................1194 Track frame and idler cushion.......................................................................................1194 Idler...............................................................................................................1196 Track roller........................................................................................................1200 Carrier roller......................................................................................................1203 Track shoe..........................................................................................................1206 Hydraulic system........................................................................................................1216 Hydraulic pump......................................................................................................1216 Control valve.......................................................................................................1226 Swing motor.........................................................................................................1232 Travel motor........................................................................................................1233 PPC valve...........................................................................................................1236 Boom drift prevention valve.........................................................................................1243 Regeneration valve (boom, arm)......................................................................................1244 Center swivel joint.................................................................................................1245 Work equipment..........................................................................................................1246 Work equipment......................................................................................................1246 Work equipment dimension............................................................................................1250 Work equipment cylinder.............................................................................................1256 80 Appendix.................................................................................................................1261 Air conditioner.........................................................................................................1263 Precautions for refrigerant.........................................................................................1263 Air conditioner component...........................................................................................1264 Configuration and function of refrigeration cycle...................................................................1266 Outline of refrigeration cycle......................................................................................1267 Air conditioner unit................................................................................................1270 Air conditioner controller..........................................................................................1275 Compressor..........................................................................................................1276 Condenser...........................................................................................................1277 Receiver drier......................................................................................................1278 Procedure for testing and troubleshooting...........................................................................1280 Circuit diagram and arrangement of connector pins...................................................................1282 System diagram......................................................................................................1284 Detail of air conditioner unit......................................................................................1286 Parts and connectors layout.........................................................................................1288 Testing air leakage (duct)..........................................................................................1291 Testing with self-diagnosis function................................................................................1292 Testing temperature control.........................................................................................1295 Testing vent (mode) changeover......................................................................................1297 Testing FRESH/RECIRC air changeover.................................................................................1300 Testing inner sensor................................................................................................1302 Testing evaporator temperature sensor...............................................................................1303 Testing sunlight sensor.............................................................................................1305 Testing (dual) pressure switch for refrigerant......................................................................1306 Testing relays......................................................................................................1307 Troubleshooting chart 1.............................................................................................1308 Troubleshooting chart 2.............................................................................................1310 Information in troubleshooting table................................................................................1312 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)....................1314 Troubleshooting for compressor and refrigerant system (Air is not cooled)...........................................1319 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)..................................1323 Troubleshooting for temperature control.............................................................................1327 Troubleshooting for vent (mode) changeover..........................................................................1330 Troubleshooting for FRESH/RECIRC air changeover.....................................................................1332 Troubleshooting for temperature sensor system.......................................................................1334 Troubleshooting with gauge pressure.................................................................................1335 Connection of service tool..........................................................................................1338 Precautions for disconnecting and connecting air conditioner piping.................................................1340 Handling of compressor oil..........................................................................................1342 90 Diagrams and drawings....................................................................................................1345 Hydraulic circuit diagram...............................................................................................1347 Symbols used in hydraulic circuit diagrams..........................................................................1347 Hydraulic circuit diagram...........................................................................................1351 Electrical circuit diagram..............................................................................................1355 Symbols used in electric circuit diagrams...........................................................................1355 Electrical circuit diagram..........................................................................................1359 Air conditioner electrical circuit diagram..........................................................................1371
KOMATSU PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0 PC700LC-8E0 EXCAVATOR SHOP MANUAL SEN05377-03 – PDF DOWNLOAD:
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- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
1 review for Komatsu PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0 PC700LC-8E0 Excavator Shop Manual SEN05377-03 – PDF DOWNLOAD
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Finnegan Turner –
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