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KOMATSU PC600LC-6 SHOP MANUAL SEBM027100 – PDF DOWNLOAD
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Description
KOMATSU PC600LC-6 SHOP MANUAL SEBM027100 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC600LC-6 SHOP MANUAL SEBM027100 – PDF DOWNLOAD
Language : English
Pages : 732
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC600LC-6 SHOP MANUAL SEBM027100 – PDF DOWNLOAD
COVER..................................................................................................................................................... 1 CONTENTS.................................................................................................................................................. 2 01 GENERAL................................................................................................................................................ 23 SPECIFICATION DRAWINGS................................................................................................................................ 24 SPECIFICATIONS........................................................................................................................................ 26 WEIGHT TABLE.......................................................................................................................................... 30 FUEL, COOLANT AND LUBRICANTS.......................................................................................................................... 34 10 STRUCTURE AND FUNCTION................................................................................................................................. 35 PARTS RELATED TO ENGINE............................................................................................................................... 36 PTO................................................................................................................................................... 38 RADIATOR, OIL COOLER.................................................................................................................................. 39 POWER TRAIN........................................................................................................................................... 40 FINAL DRIVE........................................................................................................................................... 42 SWING CIRCLE.......................................................................................................................................... 43 SWING MACHINERY....................................................................................................................................... 44 TRACK FRAME, RECOIL SPRING............................................................................................................................ 45 TRACK SHOE............................................................................................................................................ 46 HYDRAULIC PIPING DRAWING.............................................................................................................................. 47 HYDRAULIC TANK, HYDRAULIC FILTER...................................................................................................................... 49 HYDRAULIC PUMP (PISTON PUMP).......................................................................................................................... 51 LINE OIL FILTER....................................................................................................................................... 79 CONTROL VALVE......................................................................................................................................... 80 SWING MOTOR........................................................................................................................................... 95 CENTER SWIVEL JOINT...................................................................................................................................105 TRAVEL MOTOR..........................................................................................................................................106 VALVE CONTROL.........................................................................................................................................116 WORK EQUIPMENT・SWING PPC VALVE........................................................................................................................117 TRAVEL PPC VALVE......................................................................................................................................121 SERVICE PPC VALVE.....................................................................................................................................125 PPC SAFETY LOCK VALVE.................................................................................................................................128 PPC ACCUMULATOR.......................................................................................................................................128 PPC SHUTTLE VALVE.....................................................................................................................................129 SOLENOID VALVE........................................................................................................................................130 BOOM HOLDING VALVE....................................................................................................................................133 BOOM LOWER REGENERATION VALVE.........................................................................................................................137 AIR CONDITIONER.......................................................................................................................................140 ACTUAL ELECTRIC WIRING DIAGRAM........................................................................................................................141 ENGINE CONTROL........................................................................................................................................145 MACHINE CONTROL SYSTEM................................................................................................................................150 MONITOR SYSTEM........................................................................................................................................178 20 TESTING AND ADJUSTING..................................................................................................................................189 STANDARD VALUE TABLE FOR ENGINE.......................................................................................................................190 STANDARD VALUE TABLE FOR CHASSIS......................................................................................................................191 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.............................................................................................................199 TESTING AND ADJUSTING.................................................................................................................................209 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING..................................................................................................210 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)....................................................................................................211 MEASURING EXHAUST TEMPERATURE.....................................................................................................................212 MEASURING EXHAUST COLOR...........................................................................................................................213 ADJUSTING VALVE CLEARANCE.........................................................................................................................214 MEASURING COMPRESSION PRESSURE....................................................................................................................215 MEASURING BLOW-BY PRESSURE........................................................................................................................215 MEASURING ENGINE OIL PRESSURE.....................................................................................................................216 HANDLING EQUIPMENT IN FUEL CIRCUIT................................................................................................................217 RELEASING REMAINING PRESSURE IN FUEL SYSTEM.......................................................................................................217 MEASURING FUEL PRESSURE...........................................................................................................................218 REDUCED CYLINDER MODE OPERATION FOR ENGINE........................................................................................................219 BLEEDING AIR FROM FUEL SYSTEM.....................................................................................................................221 CHECK FOR LEAKAGE IN FUEL SYSTEM..................................................................................................................222 ADJUSTING ENGINE SPEED SENSOR.....................................................................................................................223 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.....................................................................................................224 TESTING AND ADJUSTING FAN BELT TENSION............................................................................................................225 HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT...................................................................................................226 TESTING WEAR OF SPROCKET..........................................................................................................................227 INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION...................................................................................................228 TESTING CLEARANCE OF SWING CIRCLE BEARING.........................................................................................................229 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT.................................................................230 TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE...........................................................................................233 TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE............................................................................................235 MEASURING PPC VALVE OUTPUT PRESSURE...............................................................................................................241 TESTING SOLENOID VALVE OUTPUT PRESSURE............................................................................................................242 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE.........................................................................................................243 TESTING TRAVEL DEVIATION..........................................................................................................................244 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.......................................................................................245 MEASURING OIL LEAKAGE ............................................................................................................................246 BLEEDING AIR......................................................................................................................................249 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.................................................................................................251 PROCEDURE FOR CHECKING DIODE......................................................................................................................252 TROUBLESHOOTING.......................................................................................................................................253 POINTS TO REMEMBER WHEN TROUBLESHOOTING...........................................................................................................254 SEQUENCE OF EVENTS IN TROUBLESHOOTING.............................................................................................................255 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..................................................................................................256 CHECKS BEFORE TROUBLESHOOTING.....................................................................................................................264 CONNECTOR TYPES AND MOUNTING LOCATIONS............................................................................................................265 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................................................................272 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM............................................................................................295 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL.............................................................................................296 METHOD OF USING JUDGEMENT TABLE...................................................................................................................310 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................312 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE..........................................................................................316 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)......................................................................................320 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................321 ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM...................................................................................................323 N-1 [E117, E118 OCCUR AT SAME TIME] MONITOR PANEL COMMUNICATION ABNORMALITY...................................................................324 N-2 [E117, E218 OCCUR AT SAME TIME] ENGINE CONTROLLER COMMUNICATION ABNORMALITY...............................................................326 N-3 [E118, E955 OCCUR AT SAME TIME] PUMP CONTROLLER COMMUNICATION ABNORMALITY.................................................................328 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE)..............................................................................................330 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED..............................................................331 JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS................................................................................339 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM..................................................................................................341 E-1 [E91b] (ABNORMALITY IN ENGINE SPEED NE SENSOR SYSTEM) IS DISPLAYED........................................................................343 E-2 [E91C] (ABNORMALITY IN ENGINE G ROTATION SENSOR SYSTEM) IS DISPLAYED......................................................................344 E-3 [E920] (ABNORMALITY IN MODEL SELECTION SYSTEM) IS DISPLAYED...............................................................................345 E-4 [E922] (ENGINE OVERRUN) IS DISPLAYED......................................................................................................346 E-5 [E924] (DROP IN ENGINE OIL PRESSURE) IS DISPLAYED.........................................................................................347 E-6 [E931] (ABNORMALITY IN FUEL CONTROL DIAL SENSOR SYSTEM) IS DISPLAYED......................................................................348 E-7 [E934] (ABNORMALITY IN ENGINE WATER TEMPERATURE (HIGH) SENSOR SYSTEM) IS DISPLAYED........................................................349 E-8 [E936] (ABNORMALITY IN ENGINE OIL PRESSURE SWITCH SYSTEM) IS DISPLAYED....................................................................350 E-9 [E93C] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM) IS DISPLAYED ........................................................................351 E-10 [E93d] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED......................................................................352 E-11 [E954] (SHORT CIRCUIT IN STARTING SWITCH C SYSTEM) IS DISPLAYED..........................................................................353 E-12 [E955] (ABNORMALITY IN NETWORK SYSTEM) IS DISPLAYED......................................................................................353 E-13 [E956] (POWER SOURCE SYSTEM ABNORMALITY 1) IS DISPLAYED..................................................................................354 E-14 [E957] (POWER SOURCE SYSTEM ABNORMALITY 2) IS DISPLAYED..................................................................................355 E-15 [E95A] (ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL) IS DISPLAYED.......................................................356 E-16 [E96A] (ABNORMALITY IN ENGINE WATER TEMPERATURE (LOW) SENSOR SYSTEM) IS DISPLAYED........................................................357 E-17 [E970] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED.....................................................................358 E-18 [E971] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED.....................................................................359 E-19 [E974] (DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED......................................................................360 E-20 [E975] (DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED......................................................................361 E-21 [E977] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM) IS DISPLAYED.............................................................362 E-22 [E979] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1) IS DISPLAYED [E97A] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2) IS DISPLAYED....363 E-23 [E97b] (FUEL SUPPLY PUMP NON-FORCE FEED 1) IS DISPLAYED [E97C] (FUEL SUPPLY PUMP NON-FORCE FEED 2) IS DISPLAYED..........................364 E-24 [E97d] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE) IS DISPLAYED...........................................................................366 E-25 [E980] (DEFECTIVE ENGINE CONTROLLER) IS DISPLAYED........................................................................................366 E-26 [E981] (DISCONNECTION IN NO.1 FUEL INJECTOR SYSTEM) IS DISPLAYED.........................................................................367 E-27 [E982] (DISCONNECTION IN NO.2 FUEL INJECTOR SYSTEM) IS DISPLAYED.........................................................................368 E-28 [E983] (DISCONNECTION IN NO.3 FUEL INJECTOR SYSTEM) IS DISPLAYED.........................................................................369 E-29 [E984] (DISCONNECTION IN NO.4 FUEL INJECTOR SYSTEM) IS DISPLAYED.........................................................................370 E-30 [E985] (DISCONNECTION IN NO.5 FUEL INJECTOR SYSTEM) IS DISPLAYED ........................................................................371 E-31 [E986] (DISCONNECTION IN NO.6 FUEL INJECTOR SYSTEM) IS DISPLAYED.........................................................................372 E-32 [E98A] (SHORT CIRCUIT IN NO.1, NO.2, NO.3 FUEL INJECTOR SYSTEM) IS DISPLAYED.............................................................373 a) DETERMINING LOCATION OF PROBLEM........................................................................................................373 b) TROUBLESHOOTING NO.1 FUEL INJECTOR SYSTEM..............................................................................................373 c) TROUBLESHOOTING NO.2 FUEL INJECTOR SYSTEM..............................................................................................374 d) TROUBLESHOOTING NO.3 FUEL INJECTOR SYSTEM..............................................................................................374 E-33 [E98b] (SHORT CIRCUIT IN NO.3, NO.4, NO.5 FUEL INJECTOR SYSTREM) IS DISPLAYED............................................................376 a) DETERMINING LOCATION OF PROBLEM........................................................................................................376 b) TROUBLESHOOTING NO.4 FUEL INJECTOR SYSTEM..............................................................................................376 c) TROUBLESHOOTING NO.5 FUEL INJECTOR SYSTEM..............................................................................................377 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)................................................................................................379 POINTS TO REMEMBER WHEN TROUBLESHOOTING CONTROLLER SYSTEM.....................................................................................380 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................381 JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS...............................................................................389 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE.........................................................................................................391 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF).....................................................................393 C-2 [E232] (SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED...........................................................................394 C-3 [E233] (DISCONNECTION IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED...........................................................................396 C-4 [E203] (SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED................................................................398 C-5 [E213] (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED................................................................400 C-6 [E201] (SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM) IS DISPLAYED..........................................................................402 C-7 [E211] (DISCONNECTION IN CO CANCEL SOLENOID SYSTEM) IS DISPLAYED..........................................................................403 C-8 [E204] (SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED.....................................................................404 C-9 [E214] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED.....................................................................405 C-10 [E206] (SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED......................................................................406 C-11 [E216] (DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED .....................................................................407 C-12 [E311] (SHORT CIRCUIT IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED.............................................................408 C-13 [E312] (DISCONNECTION IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED.............................................................409 C-14 [E217] (MODEL SELECTION INPUT ERROR) IS DISPLAYED........................................................................................410 C-15 [E224] (ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED...................................................................412 C-16 [E225] (ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED....................................................................413 C-17 [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM) IS DIAPLAYED.................................................................414 C-18 [E227] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED..........................................................................415 C-19 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)...............................................................416 C-20 [E207] SHORT CIRCUIT IN FLASHING LIGHT RELAY DRIVE SYSTEM IS DISPLAYED...................................................................418 C-21 FLASHING LIGHT RELAY DOES NOT WORK.......................................................................................................419 C-22 [E231] ABNORMALITY (SHORT CIRCUIT) IN STEP LIGHT POWER SOURCE RETENTION RELAY OUTPUT SYSTEM IS DISPLAYED.................................420 C-23 STEP LIGHT SWITCH DOES NOT WORK..........................................................................................................421 C-24 [E302] SHORT CIRCUIT IN STEP LIGHT RELAY DRIVE SYSTEM IS DISPLAYED.......................................................................422 C-25 STEP LIGHT DOES NOT LIGHT UP.............................................................................................................423 C-26 [E228] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED.......................................................................424 TROUBLESHOOTING OF PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE).................................................................................425 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE.........................................................................................................426 F-1 BIT PATTERN 20-(1) (SWING OIL PRESSURE SWITCH) DOES NOT LIGHT UP .........................................................................428 F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP.........................................................................429 F-3 BIT PATTERN 20-(3) (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP.....................................................................430 F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH) DOES NOT LIGHT UP.....................................................................431 F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DOES NOT LIGHT UP.........................................................................432 F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP........................................................................433 F-7 BIT PATTERN 21-(1) (BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP....................................................................434 F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP....................................................................435 F-9 BIT PATTERN 21-(2) (SERVICE VALVE OIL PRESSURE SWITCH) DOES NOT LIGHT UP..................................................................436 F-10 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP.................................................................................437 F-11 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP .................................................................................438 F-12 WHEN STEP LIGHT SWITCH IS ON, BIT PATTERN 24-(1) DOES NOT GO OUT.........................................................................439 F-13 WHEN HORN SWITCH IS ON, BIT PATTERN 24-(2) DOES NOT GO OUT...............................................................................440 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)..........................................................................................441 TABLE OF FAILURE MODES AND CAUSES.............................................................................................................442 BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)..............................................................................444 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER........................................................................447 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS.................................................................................448 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE.....................................................................................................450 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)....................................................................................................451 H-5 AUTO- DECELERATION DOES NOT WORK..........................................................................................................451 H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) IS SLOW OR LACKS POWER.................................................................................452 H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET)DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL).........................................................453 H-8 EXCESSIVE HYDRAULIC DRIFT.................................................................................................................453 H-9 EXCESSIVE TIME LAG........................................................................................................................454 H-10 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION..........................................................................................454 H-11 IN COMPOUND OPERATIONS WITH SWING, WORK EQUIPMENT SPEED IS SLOW..........................................................................455 H-12 IN COMPOUND OPERATIONS WITH BUCKET CURL, SWING AND OTHER WORK EQUIPMENT SPEEDS ARE SLOW..................................................455 H-13 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS.................................................................................455 H-14 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS..........................................................................456 H-15 DEVIATION IS EXCESSIVE WHEN STARTING.....................................................................................................459 H-16 TRAVEL SPEED IS SLOW.....................................................................................................................461 H-17 TRAVEL SPEED DOES NOT SWITCH.............................................................................................................462 H-18 TRAVEL DOES NOT MOVE (ONE SIDE ONLY).....................................................................................................462 H-19 DOES NOT SWING...........................................................................................................................463 H-20 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR........................................................................................464 H-21 EXCESSIVE OVERRUN WHEN STOPPING SWING....................................................................................................465 H-22 EXCESSIVE SHOCK WHEN STOPPING SWING......................................................................................................466 H-23 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING.............................................................................................466 H-24 EXCESSIVE HYDRAULIC DRIFT OF SWING.......................................................................................................467 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)................................................................................................468 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.................................................................470 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM..................................................................................................472 M-1 [E101] ABNORMALITY IN ERROR DATA) OR [E102] (ABNORMALITY IN CLOCK DATA) IS DISPLAYED......................................................474 M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT SYSTEM) IS DISPLAYED...............................................................................475 M-3 [E104] (AIR CLEANER CLOGGING DETECTION)IS DISPLAYED.......................................................................................476 M-4 [E108] (ENGINE WATER TEMPERATURE 105℃) IS DISPLAYED.......................................................................................476 M-5 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS..................................................477 M-6 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT..............................................479 M-7 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE....................................479 M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH...............................................................480 a) ENGINE OIL LEVEL CAUTION LAMP FLASHES..................................................................................................480 b) HYDRAULIC OIL LEVEL CAUTION LAMP FLASHES...............................................................................................481 M-9 PREHEATING IS NOT BEING USED BUT PREHEATING DISPLAY MONITOR LAMP LIGHTS UP................................................................482 M-10 WHEN ENGINE IS STARTED, BASIC CHECK ITEMS FLASH..........................................................................................483 M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH..........................................484 M-12 WHEN ENGINE IS STARTED,CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH......................................................................485 a) ENGINE OIL PRESSURE CAUTION LAMP FLASHES...............................................................................................485 b) CHARGE CAUTION LAMP FLASHES............................................................................................................485 c) ENGINE WATER TEMPERATURE CAUTION LAMP FLASHES..........................................................................................486 d) FUEL LEVEL CAUTION LAMP FLASHES........................................................................................................486 e) AIR CLEANER CLOGGING CAUTION LAMP FLASHES..............................................................................................487 f) HYDRAULIC OIL TEMPERATURE CAUTION LAMP FLASHES.........................................................................................488 M-13 OPERATION OF ALARM BUZZER IS NOT NORMAL..................................................................................................489 a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),BUZZER DOES NOT SOUND FOR 1 SECOND .................................................489 b) NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS...............................................................................489 M-14 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP........................................................................................491 M-15 ENGINE WATER TEMPERATURE DISPLAY IS NOT NORMAL...........................................................................................492 A) GAUGE DOES NOT GO UP...................................................................................................................492 b) GAUGES DO NOT GIVE DISPLAY (NO STAGE IS DISPLAYED).....................................................................................492 M-16 FUEL LEVEL GAUGE DISPLAY IS NOT NORMAL...................................................................................................493 a) FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL..................................................................................................493 b) FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY (NO STAGE IS DISPLAYED).........................................................................493 M-17 SWING LOCK SWITCH IS TURNED ON BUT SWING LOCK MONITOR LAMP DOES NOT LIGHT UP.............................................................495 M-18 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL (EMERGENCY),SWING LOCK MONITOR LAMP DOES NOT FLASH.......................................496 M-19 SERVICE METER DOES NOT GIVE NORMAL DISPLAY...............................................................................................497 a) SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING .................................................................................497 b) WHEN STARTING SWITCH IS OFF, SERVICE METER DOES NOT GIVE DISPLAY WHEN TIME SWITCH IS PRESSED...........................................497 M-20 DEFECTIVE FUEL LEVEL SENSOR SYSTEM.......................................................................................................498 M-21 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM.................................................................................................499 M-22 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM..............................................................................................500 M-23 WIPER IS NOT ACTUATED WHEN WIPER SWITCH IS OPERATED OR WIPER IS ACTUATED WHEN WIPER SWITCH IS NOT OPERATED...............................501 a) WIPER IS NOT ACTUATED WHEN SWITCH IS OPERATED(INCLUDING WHEN SERVICE CODE [E112],[E113] ARE DISPLAYED).................................501 b) WIPER SWITCH IS NOT BEING OPERATED, BUT WIPER IS ACTUATED..............................................................................503 M-24 ELECTRIC GREASE GUN DOES NOT WORK (MACHINES EQUIPPED WITH ELECTRIC GREASE GUN)...........................................................506 30 DISASSEMBLY AND ASSEMBLY...............................................................................................................................507 METHOD OF USING MANUAL................................................................................................................................508 PRECAUTIONS WHEN CARRYING OUT OPERATION...............................................................................................................511 SPECIAL TOOL LIST.....................................................................................................................................513 SKETCHES OF SPECIAL TOOLS.............................................................................................................................520 RADIATOR, HYDRAULIC COOLER............................................................................................................................528 REMOVAL...........................................................................................................................................528 INSTALLATION......................................................................................................................................529 ENGINE, PTO, HYDRAULIC PUMP...........................................................................................................................531 REMOVAL...........................................................................................................................................531 INSTALLATION......................................................................................................................................534 PTO ASSEMBLY..........................................................................................................................................535 REMOVAL AND INSTALLATION..........................................................................................................................535 DISASSEMBLY.......................................................................................................................................536 ASSEMBLY..........................................................................................................................................538 FUEL TANK ASSEMBLY....................................................................................................................................540 REMOVAL AND INSTALLATION..........................................................................................................................540 FINAL DRIVE ASSEMBLY..................................................................................................................................541 DISASSEMBLY.......................................................................................................................................541 ASSEMBLY..........................................................................................................................................547 TRAVEL MOTOR ASSEMBLY.................................................................................................................................554 DISASSEMBLY.......................................................................................................................................554 ASSEMBLY..........................................................................................................................................559 REVOLVING FRAME ASSEMBLY..............................................................................................................................570 REMOVAL...........................................................................................................................................570 INSTALLATION......................................................................................................................................571 SWING MOTOR ASSEMBLY .................................................................................................................................572 REMOVAL AND INSTALLATION..........................................................................................................................572 DISASSEMBLY.......................................................................................................................................573 ASSEMBLY..........................................................................................................................................577 SWING MACHINERY ASSEMBLY..............................................................................................................................584 REMOVAL AND INSTALLATION..........................................................................................................................584 DISASSEMBLY.......................................................................................................................................585 ASSEMBLY..........................................................................................................................................589 SWING CIRCLE ASSEMBLY.................................................................................................................................594 REMOVAL AND INSTALLATION..........................................................................................................................594 TRACK SHOE ASSEMBLY...................................................................................................................................595 REMOVAL...........................................................................................................................................595 INSTALLATION......................................................................................................................................596 ONE LINK IN FIELD ....................................................................................................................................597 DISASSEMBLY.......................................................................................................................................597 ASSEMBLY..........................................................................................................................................599 IDLER, RECOIL SPRING ASSEMBLY.........................................................................................................................601 REMOVAL AND INSTALLATION..........................................................................................................................601 IDLER.................................................................................................................................................602 DISASSEMBLY.......................................................................................................................................602 ASSEMBLY..........................................................................................................................................604 RECOIL SPRING ASSEMBLY................................................................................................................................606 DISASSEMBLY.......................................................................................................................................606 ASSEMBLY..........................................................................................................................................607 TRACK ROLLER ASSEMBLY.................................................................................................................................608 REMOVAL AND INSTALLATION..........................................................................................................................608 DISASSEMBLY.......................................................................................................................................609 ASSEMBLY..........................................................................................................................................610 CARRIER ROLLER ASSEMBLY...............................................................................................................................612 REMOVAL AND INSTALLATION..........................................................................................................................612 DISASSEMBLY.......................................................................................................................................613 ASSEMBLY..........................................................................................................................................614 HYDRAULIC TAMK ASSEMBLY...............................................................................................................................616 REMOVAL...........................................................................................................................................616 INSTALLATION......................................................................................................................................617 MAIN RELIEF VALVE ASSEMBLY............................................................................................................................618 DISASSEMBLY.......................................................................................................................................618 ASSEMBLY..........................................................................................................................................619 MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY...........................................................................................................620 REMOVAL...........................................................................................................................................620 INSTALLATION......................................................................................................................................621 MAIN CONTROL VALVE....................................................................................................................................622 DISASSEMBLY.......................................................................................................................................622 ASSEMBLY..........................................................................................................................................624 NO.1 AND NO.2 PUMP ASSEMBLY...........................................................................................................................626 REMOVAL...........................................................................................................................................626 INSTALLATION......................................................................................................................................627 HYDRAULIC PUMP ASSEMBLY...............................................................................................................................628 DISASSEMBLY.......................................................................................................................................628 ASSEMBLY..........................................................................................................................................638 CONTROL, PTO LUBRICATION PUMP ASSEMBLY................................................................................................................654 REMOVAL AND INSTALLATION..........................................................................................................................654 CENTER SWIVEL JOINT ASSEMBLY..........................................................................................................................655 REMOVAL AND INSTALLATION..........................................................................................................................655 DISASSEMBLY AND ASSEMBLY..........................................................................................................................656 WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................................................................657 DISASSEMBLY.......................................................................................................................................657 ASSEMBLY..........................................................................................................................................658 TRAVEL PPC VALVE ASSEMBLY.............................................................................................................................659 DISASSEMBLY ......................................................................................................................................659 ASSEMBLY..........................................................................................................................................660 BUCKET CYLINDER ASSEMBLY..............................................................................................................................661 REMOVAL...........................................................................................................................................661 INSTALLATION......................................................................................................................................662 ARM CYLINDER ASSEMBLY.................................................................................................................................663 REMOVAL...........................................................................................................................................663 INSTALLATION......................................................................................................................................664 BOOM CYLINDER ASSEMBLY................................................................................................................................665 REMOVAL...........................................................................................................................................665 INSTALLATION......................................................................................................................................666 HYDRAULIC CYLINDER ASSEMBLY...........................................................................................................................667 DISASSEMBLY.......................................................................................................................................667 ASSEMBLY..........................................................................................................................................670 BUCKET ASSEMBLY.......................................................................................................................................674 REMOVAL...........................................................................................................................................674 INSTALLATION......................................................................................................................................675 ARM ASSEMBLY..........................................................................................................................................676 REMOVAL...........................................................................................................................................676 INSTALLATION......................................................................................................................................677 BOOM ASSEMBLY.........................................................................................................................................678 REMOVAL...........................................................................................................................................678 INSTALLATION......................................................................................................................................679 OPERATOR'S CAB ASSEMBLY...............................................................................................................................680 REMOVAL...........................................................................................................................................680 INSTALLATION......................................................................................................................................681 COUNTERWEIGHT ASSEMBLY................................................................................................................................682 REMOVAL AND INSTALLATION..........................................................................................................................682 40 MAINTENANCE STANDARD...................................................................................................................................683 ENGINE MOUNT..........................................................................................................................................684 PTO...................................................................................................................................................685 SWING MACHINERY.......................................................................................................................................686 SWING CIRCUIT.........................................................................................................................................688 FINAL DRIVE...........................................................................................................................................689 TRACK FRAME AND RECOIL SPRING.........................................................................................................................691 IDLER.................................................................................................................................................692 CARRIER ROLLER........................................................................................................................................694 TRACK ROLLER..........................................................................................................................................695 TRACK SHOE............................................................................................................................................696 HYDRAULIC PUMP........................................................................................................................................701 CONTROL AND PTO LUBRICATION PUMP......................................................................................................................703 CONTROL VALVE.........................................................................................................................................704 SWING MOTOR...........................................................................................................................................710 TRAVEL MOTOR..........................................................................................................................................711 WORK EQUIPMENT・SWING PPC VALVE........................................................................................................................712 TRAVEL PPC VALVE......................................................................................................................................713 SERVICE PPC VALVE.....................................................................................................................................714 SOLENOID VALVE........................................................................................................................................715 CENTER SWIVEL JOINT...................................................................................................................................716 BOOM HOLDING VALVE....................................................................................................................................717 BOOM LOWER REGENERATION VALVE.........................................................................................................................718 HYDRAULIC CYLINDER....................................................................................................................................719 WORK EQUIPMENT........................................................................................................................................721 DIMENSIONS OF WORK EQUIPMENT..........................................................................................................................723 90 OTHERS.................................................................................................................................................727 HYDRAULIC CIRCUIT DIAGRAM.............................................................................................................................728 ELECTRIC CIRCUIT DIAGRAM (1/4)........................................................................................................................729 ELECTRIC CIRCUIT DIAGRAM (2/4)........................................................................................................................730 ELECTRIC CIRCUIT DIAGRAM (3/4)........................................................................................................................731 ELECTRIC CIRCUIT DIAGRAM (4/4)........................................................................................................................732
DESCRIPTION:
KOMATSU PC600LC-6 SHOP MANUAL SEBM027100 – PDF DOWNLOAD
FOREWORD
GENERAL
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.
S.S 25/12/24
