Komatsu Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,993 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TEN00405-03 - Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Operation & Maintenance Manual.pdf
SEN05377-03 - Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Shop Manual.pdf
GEN00101-02 - Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Field Assembly Instruction.pdf
MAIN SECTIONS
GEN00101-02 - Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Field Assembly Instruction....2
COVER....2
FOREWORD....3
CONTENTS....4
SPECIFICATIONS....7
PRECAUTIONS FOR FIELD ASSEMBLY....9
DISPOSAL OF REMOVED PARTS....10
ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE....11
KIT LAYOUT DIAGRAM....12
TRANSPORTATION....13
LIST OF TOOLS FOR FIELD ASSEMBLING....18
TIGHTENING TORQUE....19
COATING MATERIALS....24
SELECTION OF WIRE ROPES USED FOR ASSEMBLY....26
A. ASSEMBLY OF CHASSIS....27
A- 1. Installation of Left and Right Track Frames....28
A- 2. Installation of Travel Pipe....33
A- 3. Installation of Operator Cabs Left Handrail....38
A- 4. Installation of Operator Cabs Door Stopper and Striker....39
A- 5. Installation of Rearview Mirror....41
A- 6. Installation of Handrail....46
A- 7-1 Installation of Step....49
A- 7-2 Installation of Step....50
A- 8. Installation of Left Side Step....51
A- 9. Sticking Sheet to Counterweight....52
A-10. Installation of Rear View Camera....53
A-11. Installation of Counterweight....58
A-12. Installation of Step Light....60
A-13. Bleeding of Air from Travel Motor....62
A-14-1 Installation of Travel Piping Cover....63
A-14-2 Installation of Travel Piping Cover....67
A-15. Installation of Travel Motor Guard....70
A-16. Testing Track Shoe Tension....71
A-17. Check Fuel, Coolant and Oil Levels....74
B. ASSEMBLING OF WORK EQUIPMENT....77
B- 1. Assembly of Arm Cylinder....78
B- 2. Connection of Arm Cylinder Hoses....79
B- 3. Installation of Boom Cylinder....80
B- 4. Installation of Boom Cylinder Hoses....81
B- 5. Installation of Boom Foot Dust Seal....82
B- 6. Assembly of Boom Assembly....83
B- 7. Installation of Hoses from Chassis Along Top of Boom....84
B- 8. Connection of Boom Cylinder Head....86
B- 9. Installation of Arm Assembly....87
B-10. Installation of Bucket Cylinder Hoses between Boom and Bucket Cylinder....89
B-11. Installation of Bucket....90
B-12. Connection of Work Equipment Grease Piping....93
B-13. Connection of Work Equipment Wiring....94
B-14. Greasing after Assembling Work Equipment....96
B-15. Bleeding Air from Work Equipment Circuit....97
B-16. Parts to be Touched up After Field Assembly....98
C. Assembling of Work Equipment of Loading Shovel....99
C- 1. Releasing residual pressure in hydraulic circuit....100
C- 2. Pulling out boom foot pin and boom cylinder foot pin....101
C- 3. Installation of boom cylinder foot....102
C- 4. Installation of boom and arm assembly....103
C- 5. Installation of boom cylinder hoses....104
C- 6. Installation of boom cylinder rod pin....105
C- 7. Installation of boom cylinder....106
C- 8. Installation of arm cylinder hoses....107
C- 9. Installation of bucket cylinder....108
C-10. Installation of bucket cylinder hoses....109
C-11. Installation of connecting hoses between chassis and boom top....110
C-12. Installation of bottom dump cylinder hoses....111
C-13. Installation of bucket assembly....112
C-14. Installation of working lamps....114
C-15. Installation of work equipment grease piping....116
C-16. Greasing after assembling of work equipment....117
C-17. Bleeding air from work equipment circuit....118
C-18. Checking oil level in hydraulic tank and adding oil....119
D. ASSEMBLING OF COUNTERWEIGHT REMOVER....121
D- 1. Sticking Sheet to Counterweight....122
D- 2. Adjustment of Shims for Counterweight....123
D- 3. Greasing....128
D- 4. Installation of Counterweight Remover....129
D- 5. Installation of Covers....130
D- 6. Installation of Clamps....131
D- 7. Installation of Hoses....134
D- 8. Bleeding Air from Counterweight Remover Circuit....135
D- 9. Installation of Counterweight....136
D-10. Installation of Accessories....138
D-11. Check of Operation....139
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY....141
M- 1. Inspection of Oil Level in Hydraulic Tank and Refill....142
M- 2. Replacement of Return Filter (Standard Filter to Flushing Filter)....144
M- 3. Flushing of Hydraulic Circuit....147
M- 4. Failure code....149
M- 5. Operating Method of ....154
Field Assembly Inspection Report (Backhoe)....161
Field Assembly Inspection Report (Loading Shovel)....187
SEN05377-03 - Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Shop Manual....213
COVER....213
00 Index and foreword....223
Table of Contents....224
Table of Contents....224
Foreword and general information....234
Safety notice....234
How to read the shop manual....239
Explanation of terms for maintenance standard....241
Handling of hydraulic components....243
Method of disconnecting and connecting push-pull type coupler....245
Handling of electric equipment....248
How to read electric wire code....258
Precautions when performing work....261
Standard tightening torque table....264
List of abbreviation....268
Conversion table....272
01 Specification....277
Specifications....280
Specifications drawing....280
Working range drawings....282
Specifications....284
Table of weight....294
Table of fuel, coolant and lubricants....302
10 Structure and function....305
Engine and cooling system....307
Engine related parts....307
PTO....308
Cooling system....309
Power train system....310
Power train....310
Swing circle....312
Swing machinery....314
Final drive....316
Undercarriage and frame....318
Track frame and idler cushion....318
Hydraulic system....320
Hydraulic component layout....320
Valve control....322
Hydraulic tank and filter....324
Hydraulic pump (piston pump)....326
Cooling fan pump....354
Cooling fan motor....362
Control valve....368
Swing motor....384
Travel motor....392
PPC valve....413
Solenoid valve....421
PPC shuttle valve....428
Boom drift prevention valve....429
Boom LOWER regeneration valve....433
Arm regeneration valve....436
Quick return valve....439
Line oil filter....442
Center swivel joint....443
Accumulator....444
Electrical system....445
Engine control....445
Electrical control system....455
Monitor system....485
KOMTRAX system....511
Sensors....513
20 Standard value table....517
Standard value table....519
Standard value table for engine....519
Standard value table for machine....520
30 Testing and adjusting....543
Tool for testing, adjusting and troubleshooting....545
Tools for testing, adjusting, and troubleshooting....545
Engine and cooling system....549
Testing engine speed....549
Testing intake air pressure (boost pressure)....551
Testing exhaust gas temperature....552
Testing exhaust gas color....553
Testing and adjusting valve clearance....554
Testing compression pressure....555
Testing blowby pressure....557
Testing engine oil pressure....558
Testing EGR valve and bypass valve drive pressure....559
Handling fuel system parts....560
Releasing remaining pressure from fuel system....561
Testing fuel pressure....562
Cylinder cut-out test mode....563
No-injection cranking....564
Testing fuel return rate and leakage....565
Bleeding air from fuel circuit....568
Testing fuel circuit for leakage....570
Testing and adjusting alternator belt tension....571
Testing and adjusting air conditioner compressor belt tension....572
Undercarriage and frame....573
Testing swing circle bearing clearance....573
Checking and adjusting track tension....574
Hydraulic system....575
Testing and adjusting oil pressure in work equipment, swing and travel circuits....575
Testing and adjusting control circuit oil pressure....580
Testing and adjusting control oil pressure of piston pump....582
Testing servo piston movement....588
Testing PPC valve output pressure....590
Testing output pressure of solenoid valve and PPC shuttle valve....594
Adjusting play of work equipment and swing PPC vavles....600
Isolating the parts causing hydraulic drift in work equipment....601
Testing and adjusting travel deviation....603
Testing fan speed....605
Testing fan circuit oil pressure....606
Releasing remaining pressure from hydraulic circuit....607
Testing oil leakage....608
Bleeding air from each part....612
Electrical system....615
Special functions of machine monitor....615
Handling of voltage circuit of engine controller....659
Preparatory work for troubleshooting of electrical system....660
Inspection procedure of diode....665
Pm clinic....666
Pm Clinic service....666
UNDERCARRIAGE INSPECTION REPORT....678
40 Troubleshooting....681
General information on troubleshooting....688
Points to remember when troubleshooting....688
Sequence of events in troubleshooting....689
Checks before troubleshooting....690
Classification and procedures for troubleshooting....714
Failure codes table....717
Symptom and troubleshooting numbers....721
Information in troubleshooting table....724
Troubleshooting method for open circuit in wiring harness of pressure sensor system....726
Connector list and layout....728
Connection table for connector pin numbers....738
T- branch box and T- branch adapter table....774
Fuse locations....777
Troubleshooting by failure code....780
Failure code [989L00] Engine Controller Lock Caution 1....780
Failure code [989M00] Engine Controller Lock Caution 2....781
Failure code [989N00] Engine Controller Lock Caution 3....782
Failure code [AA10NX] Air Cleaner Clogging....783
Failure code [AB00KE] Charge Voltage Low....784
Failure code [B@BAZG] Eng Oil Press Low....786
Failure code [B@BAZK] Eng Oil Level Low....787
Failure code [B@BCNS] Eng Water Overheat....788
Failure code [B@BCZK] Eng Water Level Low....790
Failure code [B@HANS] Hyd Oil Overheat....792
Failure code [CA111] ECM Critical Internal Failure....794
Failure code [CA115] Eng Ne and Bkup Speed Sens Error....796
Failure code [CA122] Chg Air Press Sensor High Error....798
Failure code [CA123] Chg Air Press Sensor Low Error....800
Failure code [CA131] Throttle Sensor High Error....802
Failure code [CA132] Throttle Sensor Low Error....804
Failure code [CA135] Eng Oil Press Sensor High Error....806
Failure code [CA141] Eng Oil Press Sensor Low Error....808
Failure code [CA144] Coolant Temp Sens High Error....810
Failure code [CA145] Coolant Temp Sens Low Error....812
Failure code [CA153] Chg Air Temp Sensor High Error....814
Failure code [CA154] Chg Air Temp Sensor Low Error....816
Failure code [CA187] Sens Supply 2 Volt Low Error....818
Failure code [CA221] Ambient Press Sens High Error....820
Failure code [CA222] Ambient Press Sens Low Error....822
Failure code [CA227] Sens Supply 2 Volt High Error....824
Failure code [CA234] Eng Overspeed....825
Failure code [CA238] Ne Speed Sens Supply Volt Error....826
Failure code [CA263] Fuel Temp Sensor High Error....828
Failure code [CA265] Fuel Temp Sensor Low Error....830
Failure code [CA271] IMV/PCV1 Short Error....832
Failure code [CA272] IMV/PCV1 Open Error....833
Failure code [CA273] PCV2 Short Error....834
Failure code [CA274] PCV2 Open Error....835
Failure code [CA322] Inj #1(L#1) Open/Short Error....836
Failure code [CA323] Inj #5 (L#5) Open/Short Error....838
Failure code [CA324] Inj #3(L#3) Open/Short Error....840
Failure code [CA325] Inj #6 (L#6) Open/Short Error....842
Failure code [CA331] Inj #2(L#2) Open/Short Error....844
Failure code [CA332] Inj #4 (L#4) Open/Short Error....846
Failure code [CA342] Calibration Code Incompatibility....848
Failure code [CA351] Injectors Drive Circuit Error....849
Failure code [CA352] Sens Supply 1 Volt Low Error....850
Failure code [CA386] Sens Supply 1 Volt High Error....852
Failure code [CA441] Battery Voltage Low Error....852
Failure code [CA442] Battery Voltage High Error....853
Failure code [CA449] Rail Press Very High Error....853
Failure code [CA451] Rail Press Sensor High Error....854
Failure code [CA452] Rail Press Sensor Low Error....856
Failure code [CA553] Rail Press High Error....858
Failure code [CA554] Rail Press Sensor In Range Error....858
Failure code [CA559] Supply Pump Press Low Error 1....859
Failure code [CA689] Eng Ne Speed Sensor Error....862
Failure code [CA731] Eng Bkup Speed Sens Phase Error....864
Failure code [CA757] All Continuous Data Lost Error....865
Failure code [CA778] Eng Bkup Speed Sensor Error....866
Failure code [CA1228] EGR Valve Servo Error 1....868
Failure code [CA1625] EGR Valve Servo Error 2....869
Failure code [CA1626] BP Valve Sol Current High Error....870
Failure code [CA1627] BP Valve Sol Current Low Error....872
Failure code [CA1628] Bypass Valve Servo Error 1....874
Failure code [CA1629] Bypass Valve Servo Error 2....875
Failure code [CA1631] BP Valve Pos Sens High Error....876
Failure code [CA1632] BP Valve Pos Sens Low Error....878
Failure code [CA1633] KOMNET Datalink Timeout Error....880
Failure code [CA2185] Throt Sens Sup Volt High Error....882
Failure code [CA2186] Throt Sens Sup Volt Low Error....884
Failure code [CA2249] Rail Press Very Low Error....885
Failure code [CA2271] EGR Valve Pos Sens High Error....886
Failure code [CA2272] EGR Valve Pos Sens Low Error....888
Failure code [CA2351] EGR Valve Sol Current High Error....890
Failure code [CA2352] EGR Valve Sol Current Low Error....892
Failure code [CA2555] Grid Htr Relay Open Circuit Error....894
Failure code [CA2556] Grid Htr Relay Short Circuit Error....896
Failure code [D110KB] Battery Relay Drive Short Circuit....898
Failure code [D163KB] Flash Light Relay Short Circuit....900
Failure code [D195KA] Step Light Relay Open Circuit....902
Failure code [D195KB] Step Light Relay Short Circuit....904
Failure code [D19JKZ] Personal code relay abnormality....906
Failure code [D862KA] GPS Antenna Open Circuit....908
Failure code [DA22KK] Pump Solenoid Power Low Error....910
Failure code [DA25KP] 5V Sensor1 Power Abnormality....912
Failure code [DA29KQ] Model Selection Abnormality....914
Failure code [DA2RMC] CAN Discon (Pump Con Detected)....916
Failure code [DA80MA] Auto. Lub. Abnormal....920
Failure code [DAF8KB] Camera Power Supply Short Circuit....922
Failure code [DAFGMC] GPS Module Error....924
Failure code [DAFRMC] CAN Discon (Monitor Detected)....925
Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit....930
Failure code [DGH2KB] Hyd Oil Sensor Short....932
Failure code [DHPAMA] F Pump Press Sensor Abnormality....934
Failure code [DHPBMA] R Pump Press Sensor Abnormality....936
Failure code [DV20KB] Travel alarm short circuit....938
Failure code [DW43KA] Travel Speed Sol Open Circuit....940
Failure code [DW43KB] Travel Speed Sol Short Circuit....942
Failure code [DW45KA] Swing Brake Sol Open Circuit....944
Failure code [DW45KB] Swing Brake Sol Short Circuit....946
Failure code [DW48KA] CO Cancel Sol Open Circuit....948
Failure code [DW48KB] CO Cancel Sol Short Circuit....950
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol Open Circuit....952
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol Short Circuit....954
Failure code [DW7BKA] Fan Reverse Sol Open Circuit....956
Failure code [DW7BKB] Fan Reverse Sol Short Circuit....958
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit....960
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit....962
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit....964
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit....965
Failure code [DXA0KA] TVC Sol Open Circuit....966
Failure code [DXA0KB] TVC Sol Short Circuit....968
Failure code [DY20KA] Wiper Working Abnormality....970
Failure code [DY20MA] Wiper Parking Abnormality....974
Failure code [DY2CKA] Washer Drive Open Circuit....976
Failure code [DY2CKB] Washer Drive Short Circuit....978
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit....980
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit....984
Failure code [DY2FMA] Upper Wiper Working Abnormality....988
Failure code [DY2GKM] Wiper Select Abnormality....990
Troubleshooting of electrical system (E-mode)....994
E-1 Engine does not start (Engine does not crank)....994
E-2 Preheater does not operate....999
E-3 When starting switch is turned to ON position, machine monitor displays nothing....1003
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up....1006
E-5 Precaution item lights up while engine is running....1008
E-6 Emergency stop item lights up while engine is running....1010
E-7 Engine coolant temperature gauge does not indicate properly....1011
E-8 Fuel gauge does not indicate properly....1012
E-9 Hydraulic oil temperature gauge does not indicate properly....1014
E-10 Content of display on machine monitor is different from that of actual machine....1016
E-11 Some areas of machine monitor screen are not displayed....1016
E-12 Function switch does not operate....1016
E-13 Automatic warm-up system does not operate (in cold season)....1017
E-14 Auto-decelerator does not operate properly....1018
E-15 Working mode does not change....1019
E-16 Travel speed does not change....1020
E-17 Alarm buzzer cannot be canceled....1021
E-18 When starting switch is turned OFF, service meter is not displayed....1021
E-19 Service mode cannot be selected....1021
E-20 Any of work equipment, swing and travel does not work or cannot be locked....1022
E-21 Machine push-up function does not work or cannot be canceled....1024
E-22 Boom shockless function does not operate normally....1026
E-23 Swing brake does not operate normally....1028
E-24 Windshield wiper and window washer do not operate....1030
E-25 Travel alarm does not sound or does not stop sounding....1033
E-26 BOOM RAISE indicator is not displayed properly with monitoring function....1034
E-27 BOOM LOWER indicator is not displayed properly with monitoring function....1036
E-28 ARM IN indicator is not displayed properly with monitoring function....1038
E-29 ARM DUMP indicator is not displayed properly with monitoring function....1040
E-30 BUCKET CURL indicator is not displayed properly with monitoring function....1042
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function....1044
E-32 Swing indicator is not displayed properly with monitoring function....1046
E-33 Travel indicator is not displayed properly with monitoring function....1048
E-34 "Service" is not displayed normally by monitoring function....1050
E-35 Electric grease gun does not operate....1052
E-36 KOMTRAX system does not operate normally....1053
E-37 Bottom dump does not operate properly....1054
E-38 Horn does not sound or does not stop sounding....1057
E-39 Step light does not light up or go off....1060
Troubleshooting of hydraulic and mechanical system (H-mode)....1064
Before troubleshooting for hydraulic and mechanical systems....1064
Information in troubleshooting table (H-mode)....1069
H-1 All of work equipment, travel and swing work slow or lack power....1070
H-2 Engine speed lowers significantly or engine stalls....1072
H-3 Any of work equipment, swing and travel does not work....1074
H-4 Unusual noise is heard from around hydraulic pump....1076
H-5 Auto-decelerator is not canceled....1077
H-6 Speed or power of boom is low....1078
H-7 Speed or power of arm is low....1080
H-8 Speed or power of bucket is low....1081
H-9 Boom does not move....1082
H-10 Arm does not move....1082
H-11 Bucket does not move....1083
H-12 Bottom dump does not move....1083
H-13 Hydraulic drift of work equipment is large....1084
H-14 Time lag of work equipment is large....1085
H-15 One-touch power maximizing function does not work or is not canceled....1086
H-16 Machine push-up function does not work or is not canceled....1086
H-17 Boom/bucket speed is low at combined operation of arm and boom or bucket....1086
H-18 Speed of boom, arm, swing and travel is low at combined operation of bucket and boom, arm, swing and travel....1087
H-19 Swing speed is low at combined operation of arm and swing....1087
H-20 Machine deviates during travel....1088
H-21 Machine deviates significantly at start....1091
H-22 Machine deviates significantly during combined operation....1092
H-23 Travel speed or travel power is low....1093
H-24 One of tracks does not run (on one side alone)....1094
H-25 Travel speed does not change....1095
H-26 Upper structure does not swing....1096
H-27 Swing speed is low or acceleration is poor....1097
H-28 Upper structure overruns excessively when it stops swinging....1098
H-29 Shock is large when upper structure stops swinging....1099
H-30 Large unusual noise is heard when upper structure stops swinging40....1100
H-31 Hydraulic drift of swing is large....1101
Troubleshooting of engine (S-mode)....1102
Method of using troubleshooting chart....1102
S-1 Startability is poor....1106
S-2 Engine does not start....1108
S-3 Engine does not pick up smoothly....1112
S-4 Engine stops during operation....1113
S-5 Engine runs rough or is unstable....1114
S-6 Engine lacks power....1116
S-7 Exhaust smoke is black (incomplete combustion)....1118
S-8 Oil consumption is excessive (or exhaust smoke is blue)....1120
S-9 Oil becomes contaminated early....1121
S-10 Fuel consumption is excessive....1122
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)....1123
S-12 Oil pressure drops....1124
S-13 Oil level rises (coolant or fuel in oil)....1126
S-14 Coolant temperature rises too high (overheating)....1128
S-15 Unusual noise is made....1129
S-16 Vibration is excessive....1130
50 Disassembly and assembly....1131
General information on disassembly and assembly....1134
How to read Disassembly and Assembly....1134
Coating materials list....1136
Special tools list....1139
Sketches of special tools....1146
Engine and cooling system....1154
Removal and installation of fuel supply pump assembly....1154
Removal and installation of fuel injector assembly....1160
Removal and installation of cylinder head assembly....1163
Removal and installation of radiator assembly....1180
Removal and installation of hydraulic oil cooler assembly....1182
Removal and installation of aftercooler assembly....1184
Removal and installation of engine front seal....1186
Removal and installation of engine rear seal....1190
Removal and installation of engine, PTO and hydraulic pump assembly....1195
Removal and installation of cooling fan motor assembly....1203
Removal and installation of fuel tank assembly....1207
Power train....1208
Removal and installation of PTO assembly....1208
Disassembly and assembly of PTO assembly....1210
Disassembly and assembly of final drive assembly....1213
Removal and installation of swing motor and swing machinery assembly50....1236
Disassembly and assembly of swing machinery assembly....1238
Removal and installation of swing circle assembly....1253
Undercarriage and frame....1254
Separation and connection of track shoe assembly....1254
Disassembly and assembly of one link in field....1258
Removal and installation of idler assembly....1262
Disassembly and assembly of idler assembly....1264
Removal and installation of idler cushion assembly....1271
Disassembly and assembly of idler cushion assembly....1274
Removal and installation of track roller assembly....1278
Disassembly and assembly of track roller assembly....1280
Removal and installation of carrier roller assembly....1286
Disassembly and assembly of carrier roller assembly....1288
Removal and installation of revolving frame assembly....1294
Removal and installation of counterweight assembly....1296
Removal and installation of counterweight remover assembly....1299
Hydraulic system....1301
Removal and installation of center swivel joint assembly....1301
Disassembly and assembly of center swivel joint assembly....1302
Removal and installation of hydraulic tank assembly....1304
Removal and installation of hydraulic pump assembly....1306
Removal and installation of control valve assembly....1309
Disassembly and assembly of control valve assembly....1311
Removal and installation of swing motor assembly....1313
Disassembly and assembly of work equipment PPC valve assembly....1314
Disassembly and assembly of travel PPC valve assembly....1316
Disassembly and assembly of grease gun assembly....1318
Work equipment....1319
Removal and installation of bucket cylinder assembly....1319
Removal and installation of arm cylinder assembly....1323
Removal and installation of boom cylinder assembly....1327
Removal and installation of bottom dump cylinder assembly....1331
Removal and installation of bucket assembly....1333
Removal and installation of arm assembly....1337
Removal and installation of boom assembly....1340
Removal and installation of work equipment assembly....1344
Disassembly and assembly of work equipment cylinder assembly....1348
Cab and its attachments....1354
Removal and installation of operator's cab assembly....1354
Removal and installation of operator's cab glass (adhered window glass)....1358
Removal and installation of front window assembly....1368
Removal and installation of air conditioner unit assembly....1375
Electrical system....1379
Removal and installation of air conditioner compressor assembly....1379
Removal and installation of air conditioner condenser assembly....1382
Removal and installation of engine controller assembly....1384
Removal and installation of pump controller assembly....1386
Removal and installation of KOMTRAX terminal assembly....1388
Removal and installation of machine monitor assembly....1389
60 Maintenance standard....1391
Engine and cooling system....1393
Engine mount....1393
PTO....1395
Cooling system....1396
Power train....1397
Swing circle....1397
Swing machinery....1398
Final drive....1400
Sprocket....1402
Undercarriage and frame....1406
Track frame and idler cushion....1406
Idler....1408
Track roller....1412
Carrier roller....1415
Track shoe....1418
Hydraulic system....1428
Hydraulic pump....1428
Control valve....1438
Swing motor....1444
Travel motor....1445
PPC valve....1448
Boom drift prevention valve....1455
Regeneration valve (boom, arm)....1456
Center swivel joint....1457
Work equipment....1458
Work equipment....1458
Work equipment dimension....1462
Work equipment cylinder....1468
80 Appendix....1473
Air conditioner....1475
Precautions for refrigerant....1475
Air conditioner component....1476
Configuration and function of refrigeration cycle....1478
Outline of refrigeration cycle....1479
Air conditioner unit....1482
Air conditioner controller....1487
Compressor....1488
Condenser....1489
Receiver drier....1490
Procedure for testing and troubleshooting....1492
Circuit diagram and arrangement of connector pins....1494
System diagram....1496
Detail of air conditioner unit....1498
Parts and connectors layout....1500
Testing air leakage (duct)....1503
Testing with self-diagnosis function....1504
Testing temperature control....1507
Testing vent (mode) changeover....1509
Testing FRESH/RECIRC air changeover....1512
Testing inner sensor....1514
Testing evaporator temperature sensor....1515
Testing sunlight sensor....1517
Testing (dual) pressure switch for refrigerant....1518
Testing relays....1519
Troubleshooting chart 1....1520
Troubleshooting chart 2....1522
Information in troubleshooting table....1524
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)....1526
Troubleshooting for compressor and refrigerant system (Air is not cooled)....1531
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)....1535
Troubleshooting for temperature control....1539
Troubleshooting for vent (mode) changeover....1542
Troubleshooting for FRESH/RECIRC air changeover....1544
Troubleshooting for temperature sensor system....1546
Troubleshooting with gauge pressure....1547
Connection of service tool....1550
Precautions for disconnecting and connecting air conditioner piping....1552
Handling of compressor oil....1554
90 Diagrams and drawings....1557
Hydraulic circuit diagram....1559
Symbols used in hydraulic circuit diagrams....1559
Hydraulic circuit diagram....1563
Electrical circuit diagram....1567
Symbols used in electric circuit diagrams....1567
Electrical circuit diagram....1571
Air conditioner electrical circuit diagram....1583
TEN00405-03 - Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Operation & Maintenance Manual....1592
COVER....1592
FOREWORD....1593
BEFORE READING THIS MANUAL....1594
SAFETY INFORMATION....1595
INTRODUCTION....1596
USE OF MACHINE....1596
DIRECTIONS OF MACHINE....1596
VISIBILITY FROM OPERATOR'S SEAT....1597
PRODUCT INFORMATION....1599
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....1599
EPA REGULATIONS, ENGINE NUMBER PLATE....1599
SERVICE METER LOCATION....1600
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....1600
CONTENTS....1601
SAFETY....1605
SAFETY....1606
SAFETY LABELS....1609
LOCATION OF SAFETY LABELS....1610
SAFETY LABELS....1611
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....1617
PRECAUTIONS BEFORE STARTING OPERATION....1617
PREPARATIONS FOR SAFE OPERATION....1617
FIRE PREVENTION....1619
DO NOT GET CAUGHT IN WORK EQUIPMENT....1622
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....1622
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS....1623
UNAUTHORIZED MODIFICATION....1623
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....1624
PRECAUTIONS RELATED TO CAB GLASS....1624
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....1624
PRECAUTIONS FOR OPERATION....1625
PRECAUTIONS FOR JOBSITE....1625
STARTING ENGINE....1627
OPERATION....1629
TRANSPORTATION....1636
TOWING....1637
LIFTING OBJECTS WITH BUCKET....1638
PRECAUTIONS FOR MAINTENANCE....1639
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....1639
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....1643
OPERATION....1649
MACHINE VIEW ILLUSTRATIONS....1650
OVERALL MACHINE VIEW....1650
CONTROLS AND GAUGES....1651
DETAILED CONTROLS AND GAUGES....1653
MONITORING SYSTEM....1653
SWITCHES....1721
CONTROL LEVERS AND PEDALS....1728
SUN ROOF....1731
WINDSHIELD....1732
EMERGENCY ESCAPE HAMMER....1738
DOOR LOCK....1738
CAP WITH LOCK....1739
HOT AND COOL BOX....1741
MAGAZINE BOX....1741
ASHTRAY....1741
AIR CONDITIONER CONTROLS....1742
RADIO....1755
FUSE....1760
CIRCUIT BREAKER....1761
CONTROLLER....1762
TOOL BOX....1762
GREASE PUMP....1763
FIRE EXTINGUISHER....1766
MACHINE OPERATIONS AND CONTROLS....1767
BEFORE STARTING ENGINE....1767
STARTING ENGINE....1787
AFTER STARTING ENGINE....1790
STOPPING THE ENGINE....1800
MACHINE OPERATION....1801
STEERING THE MACHINE....1805
SWINGING....1807
WORK EQUIPMENT CONTROLS AND OPERATIONS....1808
WORKING MODE....1810
PROHIBITED OPERATIONS....1813
GENERAL OPERATION INFORMATION....1818
TRAVELING ON SLOPES....1820
ESCAPE FROM MUD....1822
RECOMMENDED APPLICATIONS....1823
BUCKET REPLACEMENT....1824
PARKING MACHINE....1826
MACHINE INSPECTION AFTER DAILY WORK....1827
LOCKING....1828
TRANSPORTATION....1829
TRANSPORTATION PROCEDURE....1829
LIFTING MACHINE....1829
SHIPPING MACHINE INFORMATION....1830
TRANSPORTATION POSTURE....1831
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....1837
COLD WEATHER OPERATION....1839
COLD WEATHER OPERATION INFORMATION....1839
AFTER DAILY WORK COMPLETION....1841
AFTER COLD WEATHER SEASON....1841
LONG TERM STORAGE....1842
BEFORE STORAGE....1842
DURING STORAGE....1842
AFTER STORAGE....1843
STARTING MACHINE AFTER LONG-TERM STORAGE....1843
TROUBLES AND ACTIONS....1844
RUNNING OUT OF FUEL....1844
PHENOMENA THAT ARE NOT FAILURES....1845
TOWING THE MACHINE....1846
SEVERE JOB CONDITION....1847
DISCHARGED BATTERY....1847
OTHER TROUBLE....1851
MAINTENANCE....1857
MAINTENANCE INFORMATION....1858
OUTLINE OF SERVICE....1860
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....1860
ELECTRIC SYSTEM MAINTENANCE....1863
WEAR PARTS....1864
WEAR PARTS LIST....1864
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....1865
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....1867
TIGHTENING TORQUE SPECIFICATIONS....1868
TIGHTENING TORQUE LIST....1868
SAFETY CRITICAL PARTS....1869
SAFETY CRITICAL PARTS LIST....1870
MAINTENANCE SCHEDULE....1871
MAINTENANCE SCHEDULE CHART....1871
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....1873
MAINTENANCE PROCEDURE....1874
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)....1874
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)....1874
WHEN REQUIRED....1875
CHECK BEFORE STARTING....1899
EVERY 10 HOURS MAINTENANCE....1900
EVERY 100 HOURS MAINTENANCE....1903
EVERY 250 HOURS MAINTENANCE....1904
EVERY 500 HOURS MAINTENANCE....1910
EVERY 1000 HOURS MAINTENANCE....1921
EVERY 2000 HOURS MAINTENANCE....1932
EVERY 4000 HOURS MAINTENANCE....1939
EVERY 5000 HOURS MAINTENANCE....1942
EVERY 8000 HOURS MAINTENANCE....1943
SPECIFICATIONS....1945
SPECIFICATIONS....1946
ATTACHMENTS AND OPTIONS....1951
GENERAL PRECAUTIONS FOR SAFETY....1952
PRECAUTIONS WHEN SELECTING....1952
READ THE INSTRUCTION MANUAL THOROUGHLY....1952
PRECAUTIONS WHEN REMOVING OR INSTALLING....1952
PRECAUTIONS WHEN USING....1952
ATTACHMENT GUIDE....1953
COMBINATIONS OF WORK EQUIPMENT....1954
TRACK SHOES SELECTION....1957
HANDLING COUNTERWEIGHT REMOVER....1958
HANDLING MACHINES EQUIPPED WITH KOMTRAX....1967
BASIC PRECAUTIONS....1967
LOADING SHOVEL....1969
EXPLANATION OF COMPONENTS....1970
SWITCHES....1970
FUSE....1973
OPERATIONS....1974
OPERATION OF WORK EQUIPMENT....1974
PRECAUTIONS DURING OPERATION....1976
PRECAUTIONS FOR OPERATION....1979
LOADING SHOVEL WORK....1981
TRANSPORTATION....1982
MACHINE CONFIGURATION FOR TRANSPORT....1982
WEAR PARTS....1983
WEAR PARTS LIST....1983
MAINTENANCE....1984
CHECK BEFORE STARTING....1984
EVERY 10 HOURS MAINTENANCE....1986
EVERY 5000 HOURS MAINTENANCE....1987
SPECIFICATION....1988
COMBINATION OF WORK EQUIPMENT....1989
COMBINATION OF WORK EQUIPMENT....1989
INDEX....1991
