Komatsu Hydraulic Excavators PC600, PC600LC Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC600-6, PC600LC-6, PC600-7, PC600LC-7, PC600-8, PC600LC-8, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC600-6, PC600LC-6, PC600-7, PC600LC-7, PC600-8, PC600LC-8 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: 6,609 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN00128-16 - Hydraulic Excavator PC600-8, PC600LC-8 Shop Manual.pdf
SEBM031206 - Hydraulic Excavator PC600-7, PC600LC-7 Shop Manual.pdf
SEBM017111 - Hydraulic Excavator PC600-6, PC600LC-6 Shop Manual.pdf
SEBM027100K - Hydraulic Excavator PC600LC-6 Shop Manual Supplement for Machines Built To Cold Weather Specifications (-50°C) (use with SEBM017100 & revisions).pdf
UEAM005000 - Hydraulic Excavator PC600-8, PC600LC-8 Operation & Maintenance Manual.pdf
TEN00346-02 - Hydraulic Excavator PC600-8, PC600LC-8 Operation & Maintenance Manual.pdf
TEN00118-07 - Hydraulic Excavator PC600-8, PC600LC-8 Operation & Maintenance Manual.pdf
TEN00037-02 - Hydraulic Excavator PC600-7, PC600LC-7 Operation & Maintenance Manual.pdf
SEAW004900 - Hydraulic Excavator (Loading Shovel) PC600-6, PC600LC-6 Field Assembly Manual.pdf
SEAW002802 - Hydraulic Excavator PC600-6, PC600LC-6 Field Assembly Manual.pdf
SEAW001700 - Hydraulic Excavator PC600-6 Field Assembly Instruction.pdf
SEAM053202T - Hydraulic Excavator GALEO PC600-7, PC600LC-7 Operation & Maintenance Manual.pdf
SEAM046200 - Hydraulic Excavator PC600-6, PC600LC-6 avance Operation & Maintenance Manual.pdf
SEAM022108T - Hydraulic Excavator PC600-6, PC600LC-6 Operation & Maintenance Manual.pdf
SEAM022100 - Hydraulic Excavator PC600-6, PC600LC-6 avance Operation & Maintenance Manual.pdf
GEN00043-04 - Hydraulic Excavator PC600-8, PC600LC-8 Field Assembly Instruction.pdf
GEN00013-01 - Hydraulic Excavator PC600-7 Field Assembly Instruction.pdf
MAIN SECTIONS
GEN00013-01 - Hydraulic Excavator PC600-7 Field Assembly Instruction....3
COVER....3
FOREWORD....4
CONTENTS....5
SPECIFICATIONS....6
FIELD ASSEMBLING....7
ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE....8
TRANSPORTATION....10
PACKING STYLE FOR TRANSPORTATION....10
LIST OF TOOLS FOR FIELD ASSEMBLING....14
STANDARD TIGHTENING TORQUE....15
A. ASSEMBLY OF BASE MACHINE....19
A-1. INSTALLATION OF LEFT AND RIGHT TRACK FRAMES....20
A-2. INSTALLATION OF TRAVEL PIPE....23
A-3. INSTALLATION OF TOP GUARD....25
A-4. INSTALLATION OF REARVIEW MIRROR....26
A-5. INSTALLATION OF HANDRAIL....29
A-6. INSTALLATION OF STEP....32
A-7. INSTALLATION OF LEFT SIDE STEP....33
A-8. STICKING SEAT TO COUNTERWEIGHT....34
A-9. REMOVAL OF MUFFLER TAIL PIPE....35
A-10. INSTALLATION OF COUNTERWEIGHT....36
A-11. INSTALLATION OF MUFFLER TAIL PIPE....37
A-12. INSTALLATION OF ORBCOMM ANTENNA (IF EQUIPPED)....38
A-13. INSTALLATION OF STEP LIGHT....39
A-14. EXTENSION OF TRACK FRAME GAUGE....41
A-15. INSTALLATION OF TRAVEL PIPING COVER....45
A-16. TESTING TRACK SHOE TENSION....46
A-17. INSPECTION OF OIL AMOUNT AND WATER AMOUNT....49
A-18. PARTS TO BE TOUCHED UP AFTER FIELD ASSEMBLY....51
B. ASSEMBLING OF WORK EQUIPMENT....52
B-1. ASSEMBLY OF BOOM FOOT PIN, BOOM CYLINDER FOOT PIN....53
B-2. ASSEMBLY OF BOOM ASSEMBLY....54
B-3. INSTALLATION OF BOOM CYLINDER FOOT....55
B-4. INSTALLATION OF BOOM CYLINDER HOSES....56
B-5. INSTALLATION OF HOSES FROM CHASSIS ALONG TOP OF BOOM....57
B-6. ASSEMBLY OF BOOM CYLINDER....58
B-7. ASSEMBLY OF ARM CYLINDER....59
B-8. INSTALLATION OF ARM CYLINDER HOSES....60
B-9. INSTALLATION OF ARM ASSEMBLY....61
B-10. INSTALLATION OF BUCKET CYLINDER HOSES BETWEEN BOOM AND BUCKET CYLINDER....63
B-11. INSTALLATION OF BUCKET....64
B-12. CONNECTION OF WORK EQUIPMENT GREASE PIPING....65
B-13. CONNECTION OF WORK EQUIPMENT WIRING....66
B-14. GREASING AFTER ASSEMBLING WORK EQUIPMENT....68
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY....69
M-1. INSPECTION OF OIL LEVEL IN HYDRAULIC TANK AND REFILL....70
M-2. REPLACEMENT OF RETURN FILTER (STANDARD FILTER TO FLUSHING FILTER)....72
M-3. FLUSHING OF HYDRAULIC CIRCUIT....75
FIELD ASSEMBLY INSPECTION REPORT (BACKHOE)....77
GEN00043-04 - Hydraulic Excavator PC600-8, PC600LC-8 Field Assembly Instruction....90
FOREWORD....90
CONTENTS....91
SPECIFICATIONS....94
PRECAUTIONS FOR FIELD ASSEMBLY....95
DISPOSAL OF REMOVED PARTS....96
ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE....97
KIT LAYOUT DIAGRAM....98
TRANSPORTATION....99
LIST OF TOOLS FOR FIELD ASSEMBLING....104
TIGHTENING TORQUE....106
A. ASSEMBLY OF CHASSIS....112
A-1. Installation of Left and Right Track Frames....113
A-2. Installation of Travel Pipe....117
A-3. Installation of Operator Cabs Left Handrail....119
A-4. Installation of Operator Cabs Door Stopper and Striker....120
A-5. Installation of Rearview Mirror....122
A-6. Installation of Handrail....126
A-7. Installation of Step....129
A-8. Installation of Left Side Step....130
A-9. Sticking Sheet to Counterweight....131
A-10. Installation of Counterweight....132
A-11. Installation of Step Light....133
A-12. Installation of Travel Piping Cover....135
A-13. Testing Track Shoe Tension....139
A-14. Check Fuel, Coolant and Oil Levels....142
B. ASSEMBLING OF WORK EQUIPMENT....146
B-1. Assembly of Arm Cylinder....147
B-2. Connection of Arm Cylinder Hoses....148
B-3. Installation of Boom Cylinder....149
B-4. Installation of Boom Foot Dust Seal....150
B-5. Assembly of Boom Assembly....151
B-6. Installation of Boom Cylinder Hoses....152
B-7. Installation of Hoses from Chassis Along Top of Boom....153
B-8. Connection of Boom Cylinder Head....154
B-9. Installation of Arm Assembly....155
B-10. Installation of Bucket Cylinder Hoses between Boom and Bucket Cylinder....157
B-11. Installation of Bucket....158
B-12. Connection of Work Equipment Grease Piping....159
B-13. Connection of Work Equipment Wiring....160
B-14. Greasing after Assembling Work Equipment....162
B-15. Bleeding Air from Work Equipment Circuit....163
B-16. Parts to be Touched up After Field Assembly....164
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY....166
M-1. Inspection of Oil Level in Hydraulic Tank and Refill....167
M-2. Replacement of Return Filter (Standard Filter to Flushing Filter)....169
M-3. Flushing of Hydraulic Circuit....172
M-4. Error Code....174
M-5. Operating Method of Monitoring....179
D. ASSEMBLING OF COUNTERWEIGHT REMOVER....184
D-1. Sticking Sheet to Counterweight....185
D-2. Adjustment of Shims for Counterweight....186
D-3. Greasing....191
D-4. Installation of Counterweight Remover....192
D-5. Installation of Covers....193
D-6. Installation of Clamps....194
D-7. Installation of Hoses....197
D-8. Bleeding Air from Counterweight Remover Circuit....198
D-9. Installation of Counterweight....199
D-10. Check of Operation....201
Field Assembly Inspection Report (Backhoe)....202
SEAM022100 - Hydraulic Excavator PC600-6, PC600LC-6 avance Operation & Maintenance Manual....228
SEAM022108T - Hydraulic Excavator PC600-6, PC600LC-6 Operation & Maintenance Manual....462
COVER....462
FOREWORD....463
FOREWORD....464
SAFETY INFORMATION....467
INTRODUCTION....469
DIRECTIONS OF MACHINE....469
BREAKING-IN THE NEW MACHINE....469
PRODUCT INFORMATION....470
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION....470
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION....470
SERVICE METER LOCATION....471
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....471
CONTENTS....472
SAFETY....476
SAFETY INFORMATION....477
SAFETY LABELS....479
LOCATION OF SAFETY LABELS....480
SAFETY LABELS....481
SAFETY INFORMATION....486
SAFETY RULES....486
IF ABNORMALITIES ARE FOUND....486
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS....486
FIRE EXTINGUISHER AND FIRST AID KIT....486
SAFETY EQUIPMENT....486
KEEP MACHINE CLEAN....487
KEEP OPERATOR'S COMPARTMENT CLEAN....487
LEAVING OPERATOR'S SEAT WITH LOCK....487
HANDRAILS AND STEPS....488
MOUNTING AND DISMOUNTING....488
NO PERSONS ON ATTACHMENTS....488
BURN PREVENTION....489
FIRE PREVENTION AND EXPLOSION PREVENTION....489
ACTION IF FIRE OCCURS....490
WINDSHIELD WASHER FLUID....490
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION....490
ATTACHMENT INSTALLATION....491
ATTACHMENT COMBINATIONS....491
CAB WINDOW GLASSES....491
UNAUTHORIZED MODIFICATIONS....491
SAFETY AT JOBSITE....491
WORKING ON LOOSE GROUND....491
DISTANCE TO HIGH VOLTAGE CABLES....492
ENSURE GOOD VISIBILITY....492
VENTILATION FOR ENCLOSED AREA....493
SIGNALMAN'S SIGNAL AND SIGNS....493
EMERGENCY EXIT FROM OPERATOR'S CAB....493
ASBESTOS DUST HAZARD PREVENTION....493
SAFETY MACHINE OPERATION....494
STARTING ENGINE....494
CHECKS BEFORE STARTING ENGINE....494
SAFETY RULES FOR STARTING ENGINE....494
STARTING ENGINE IN COLD WEATHER....494
OPERATION....496
CHECKS BEFORE OPERATION....496
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS....496
SAFETY RULES FOR TRAVELING....497
TRAVELING ON SLOPES....497
OPERATIONS ON SLOPES....498
PROHIBITED OPERATIONS....499
OPERATIONS ON SNOW....500
PARKING MACHINE....501
TRANSPORTATION....502
LOADING AND UNLOADING....502
SHIPPING THE MACHINE....502
BATTERY....503
BATTERY HAZARD PREVENTION....503
STARTING ENGINE WITH BOOSTER CABLES....504
TOWING....505
SAFETY RULES FOR TOWING....505
LIFTING OBJECTS WITH BUCKET....506
SAFETY RULES FOR LIFTING OBJECTS....506
SAFETY MAINTENANCE INFORMATION....507
WARNING TAG....507
KEEP WORK PLACE CLEAN AND TIDY....507
APPOINT LEADER WHEN WORKING WITH OTHERS....507
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE....508
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....509
PROPER TOOLS....509
ACCUMULATOR....509
PERSONNEL....510
ATTACHMENTS....510
WORK UNDER THE MACHINE....510
NOISE....510
WHEN USING HAMMER....510
WELDING WORKS....511
REMOVING BATTERY TERMINALS....511
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION....511
DO NOT DISASSEMBLE RECOIL SPRINGS....511
SAFETY RULES FOR HIGH-PRESSURE OIL....512
PRECAUTION FOR HIGH FUEL PRESSURE....512
SAFETY HANDLING HIGH-PRESSURE HOSES....512
PRECAUTION FOR HIGH VOLTAGE....512
WASTE MATERIALS....513
AIR CONDITIONER MAINTENANCE....513
COMPRESSED AIR....513
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....513
OPERATION....514
MACHINE VIEW ILLUSTRATIONS....515
OVERALL MACHINE VIEW....515
CONTROLS AND GAUGES....516
DETAILED CONTROLS AND GAUGES....517
MONITORING SYSTEM....517
SWITCHES....531
CONTROL LEVERS AND PEDALS....537
SUN ROOF....540
WINDSHIELD....541
EMERGENCY EXIT FROM OPERATOR'S CAB....544
DOOR LOCK....544
CAP WITH LOCK....545
HOT AND COOL BOX....546
LUGGAGE BOX....546
ASHTRAY....547
AIR CONDITIONER CONTROLS....548
RADIO....554
AUXILIARY ELECTRIC POWER....559
FUSE....559
CIRCUIT BREAKER....560
CONTROLLERS....561
TOOL BOX....561
GREASE PUMP....562
ACCUMULATOR....565
MACHINE OPERATIONS AND CONTROLS....566
BEFORE STARTING ENGINE....566
STARTING ENGINE....580
AFTER STARTING ENGINE....584
STOPPING THE ENGINE....590
MACHINE OPERATION....591
STEERING THE MACHINE....595
SWINGING....597
WORK EQUIPMENT CONTROLS AND OPERATIONS....598
WORKING MODE....599
PROHIBITED OPERATIONS....600
GENERAL OPERATION INFORMATION....602
TRAVELING ON SLOPES....603
ESCAPE FROM MUD....605
RECOMMENDED APPLICATIONS....606
BUCKET REPLACEMENT....607
PARKING MACHINE....609
CHECK AFTER SHUT OFF ENGINE....610
MACHINE INSPECTION AFTER DAILY WORK....610
LOCKING....611
TRANSPORTATION....612
PRECAUTIONS FOR TRANSPORTATION....612
LIFTING MACHINE....612
SHIPPING MACHINE INFORMATION....613
TRANSPORTATION POSTURE....614
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....619
COLD WEATHER OPERATION....621
COLD WEATHER OPERATION INFORMATION....621
AFTER DAILY WORK COMPLETION....623
AFTER COLD WEATHER SEASON....623
LONG TERM STORAGE....624
BEFORE STORAGE....624
DURING STORAGE....624
AFTER STORAGE....624
STARTING MACHINE AFTER LONG-TERM STORAGE....625
TROUBLES AND ACTIONS....626
RUNNING OUT OF FUEL....626
PHENOMENA THAT ARE NOT FAILURES....628
TOWING THE MACHINE....629
SEVERE JOB CONDITION....629
DISCHARGED BATTERY....630
OTHER TROUBLE....634
MAINTENANCE....639
MAINTENANCE INFORMATION....640
LUBRICANTS,COOLANT AND FILTERS....642
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....642
ELECTRIC SYSTEM MAINTENANCE....644
WEAR PARTS....645
WEAR PARTS LIST....645
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS....646
PROPER SELECTION....646
TIGHTENING TORQUE SPECIFICATIONS....650
TIGHTENING TORQUE LIST....650
SAFETY CRITICAL PARTS....652
SAFETY CRITICAL PARTS LIST....652
MAINTENANCE SCHEDULE....653
MAINTENANCE SCHEDULE CHART....653
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....655
MAINTENANCE PROCEDURE....656
WHEN REQUIRED....656
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....656
CLEAN INSIDE OF COOLING SYSTEM....661
CHECK AND TIGHTEN TRACK SHOE BOLTS....663
CHECK AND ADJUST TRACK TENSION....664
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)....666
ADJUST BUCKET CLEARANCE....667
REPLACE OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER....668
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID....668
CHECK AND ADJUST AIR CONDITIONER....669
CLEAN LINE FILTER,REMOVE DIRT....670
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT....671
BLEEDING AIR FROM HYDRAULIC SYSTEM....672
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT....675
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT)....676
CHECK BEFORE STARTING....677
EVERY 10 HOURS MAINTENANCE....678
LUBRICATING....678
EVERY 100 HOURS MAINTENANCE....681
SWING MACHINERY CASE OIL-CHECK/ADD....681
EVERY 250 HOURS MAINTENANCE....682
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....682
CHECK LEVEL OF BATTERY ELECTROLYTE....683
LUBRICATE SWING CIRCLE....685
CHANGE OIL LEVEL IN P.T.O CASE, ADD OIL....686
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS....686
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST....687
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....688
CHECK, CLEAN FUEL TANK STRAINER....689
EVERY 500 HOURS MAINTENANCE....690
REPLACE FUEL FILTER CARTRIDGE....690
CHECK SWING PINION GREASE LEVEL, ADD GREASE....691
REPLACE BREATHER FILTER ELEMENT IN HYDRAULIC TANK....692
CLEAN HYDRAULIC TANK STRAINER....693
REPLACE HYDRAULIC OIL FILTER ELEMENT....694
CLEAN, CHECK RADIATOR FIN, OIL COOLER FIN, FUEL COOLER FIN, CONDENSER FIN (MACHINES EQUIPMENT WITH AIR CONDITIONER)....695
CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)....696
CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER....697
CHECK FAN BELT....697
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....698
EVERY 1000 HOURS MAINTENANCE....700
CHANGE OIL IN SWING MACHINERY CASE....700
CHANGE OIL IN P.T.O CASE....701
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER....701
CHECK PLAY TURBOCHARGER ROTOR....701
REPLACE CORROSION RESISTOR CARTRIDGE....702
CHECK WELDED STRUCTURE....702
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)....704
EVERY 2000 HOURS MAINTENANCE....705
CHANGE OIL IN FINAL DRIVE CASE....705
CHECK INJECTOR....705
CLEAN ENGINE BREATHER....706
CLEAN, CHECK TURBOCHARGER....706
CHECK ALTERNATOR, STARTING MOTOR....706
CHECK ENGINE VALVE CLEARANCE, ADJUST....706
EVERY 4000 HOURS MAINTENANCE....707
CHECK WATER PUMP....707
CHECK VIBRATION DAMPER....707
CHECK FAN PULLEY AND TENSION PULLEY....707
CHECK AIR COMPRESSOR, ADJUST....707
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER....708
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER....709
REPLACE INJECTOR NOZZLE ASSEMBLY....709
EVERY 5000 HOURS MAINTENANCE....710
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER....710
EVERY 8000 HOURS MAINTENANCE....712
REPLACE HIGH-PRESSURE PIPING CLAMP....712
REPLACE FUEL SPRAY PREVENTION CAP....712
SPECIFICATIONS....713
SPECIFICATIONS....714
ATTACHMENTS, OPTIONS....716
GENERAL PRECAUTIONS FOR SAFETY....717
PRECAUTIONS WHEN SELECTING....717
READ THE INSTRUCTION MANUAL THOROUGHLY....717
PRECAUTIONS WHEN REMOVING OR INSTALLING....717
PRECAUTIONS WHEN USING....717
BUCKET WITH HOOK....718
HOOK CANDMON....718
PROHIBITED OPERATIONS....718
ATTACHMENT GUIDE....719
COMBINATIONS OF WORK EQUIPMENT....719
TACK SHOES SELECTION....720
LOADING SHOVEL....721
EXPLANATION OF COMPONENTS....722
SWITCHES....722
OPERATIONS ....724
OPERATION OF WORK EQUIPMENT....724
PRECAUTIONS DURING OPERATION....726
EXCAVATOR WORK....730
PRECAUTIONS WHEN DISASSEMBLING MACHINE....731
RELEASING PRESSURE....731
TRANSPORTATION....732
MACHINE CONFIGURATION FOR TRANSPORT....732
WEAR PARTS....733
WEAR PARTS LIST....733
MAINTENANCE....734
CHECK BEFORE STARTING....734
EVERY 10 HOURS MAINTENANCE....736
EVERY 5000 HOURS MAINTENANCE....737
SPECIFICATION....739
COMBINATION OF WORK EQUIPMENT....740
COMBINATION OF WORK EQUIPMENT....740
INDEX....742
SEAM046200 - Hydraulic Excavator PC600-6, PC600LC-6 avance Operation & Maintenance Manual....745
SEAM053202T - Hydraulic Excavator GALEO PC600-7, PC600LC-7 Operation & Maintenance Manual....1007
SEAW001700 - Hydraulic Excavator PC600-6 Field Assembly Instruction....1306
SEAW002802 - Hydraulic Excavator PC600-6, PC600LC-6 Field Assembly Manual....1361
SEAW004900 - Hydraulic Excavator (Loading Shovel) PC600-6, PC600LC-6 Field Assembly Manual....1486
SEBM017111 - Hydraulic Excavator PC600-6, PC600LC-6 Shop Manual....1535
COVER PAGE....1535
CONTENTS....1536
LIST OF REVISED PAGES....1537
01 GENERAL ....1563
SPECIFICATIONS....1564
WEIGHT TABLE....1574
FUEL, COOLANT AND LUBRICANTS....1578
10 STRUCTURE AND FUNCTION....1579
PARTS RELATED TO ENGINE....1580
PTO....1582
RADIATOR, OIL COOLER....1583
POWER TRAIN....1584
FINAL DRIVE....1586
SWING CIRCLE....1587
SWING MACHINERY....1588
TRACK FRAME, RECOIL SPRING....1589
TRACK SHOE....1590
HYDRAULIC PIPING DRAWING....1592
HYDRAULIC TANK, HYDRAULIC FILTER....1594
HYDRAULIC PUMP (PISTON PUMP)....1597
SERVO VALVE....1600
TVC VALVE....1607
CO+NC VALVE....1613
SERVO VALVE (NO.2 FRONT)....1623
LINE OIL FILTER....1625
CONTROL VALVE....1626
TRAVEL SHUTTLE VALVE....1632
STRAIGHT-TRAVEL VALVE....1635
SWING PRIORITY VALVE....1637
ARM THROTTLE VALVE....1639
SWING MOTOR....1641
SWING BRAKE....1645
SAFETY VALVE....1646
REVERSE PREVENTION VALVE....1648
CENTRAL SWIVEL JOINT....1651
TRAVEL MOTOR....1652
PARKING BRAKE....1656
VALVE CONTROL....1662
WORK EQUIPMENT - SWING PPC VALVE....1664
TRAVEL PPC VALVE....1668
SERVICE PPC VALVE....1672
PPC SAFETY LOCK VALVE....1675
PPC ACCUMULATOR....1675
PPC SHUTTLE VALVE....1676
SOLENOID VALVE....1677
BUCKET CURL HI CANCEL....1679
BOOM HOLDING VALVE....1680
BOOM LOWER REGENERATION VALVE....1684
AIR CONDITIONER....1687
ACTUAL ELECTRIC WIRING DIAGRAM....1688
ENGINE CONTROL....1696
MACHINE CONTROL SYSTEM....1707
MACHINE CONTROL SYSTEM DIAGRAM....1708
MONITOR SYSTEM....1742
20 TESTING AND ADJUSTING....1759
STANDARD VALUE TABLE FOR ENGING....1760
STANDARD VALUE TABLE FOR CHASSIS....1763
STANDARD VALUE TABLE FOR ELECTRICAL PARTS....1773
TESTING AND ADJUSTING....1791
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING....1792
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)....1793
MEASURING EXHAUST TEMPERATURE....1794
MEASURING EXHAUST COLOR....1795
ADJUSTING VALVE CLEARANCE....1796
MEASURING COMPRESSION PRESSURE....1797
MEASURING BLOW-BY PRESSURE....1797
MEASURING ENGINE OIL PRESSURE....1798
HANDLING EQUIPMENT IN FUEL CIRCUIT....1799
RELEASING REMAINING PRESSURE IN FUEL SYSTEM....1799
MEASURING FUEL PRESSURE....1800
REDUCED CYLINDER OPERATION FOR ENGINE....1801
BLEEDING AIR FROM FUEL SYSTEM....1803
CHECK FOR LEAKAGE IN FUEL SYSTEM....1804
ADJUSTING ENGINE SPEED SENSORY....1805
TESTING AND ADJUSTING ALTERNATOR BELT TENSION....1806
TESTING AND ADJUSTING FAN BELT TENSION....1807
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT....1808
TESTING AND ADJUSTING AIR CONDITIONAL COMPRESSOR DRIVE BELT TENSION....1809
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE....1810
TESTING WEAR OF SPROCKET....1811
TESTING AND ADJUSTING TRACK SHOE TENSION....1812
TESTING CLEARANCE OF SWING CIRCLE BEARING....1813
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT....1814
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE....1817
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE....1819
MEASURING PPC VALVE OUTPUT PRESSUSRE....1825
TESTING SOLENOID VALVE OUTPUT PRESSURE....1826
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE....1827
TESTING TRAVEL DEVIATION....1828
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT....1829
MEASURING OIL LEAKAGE....1830
BLEEDING AIR....1833
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....1835
PROCEDURE FOR CHECKING DIODE....1836
TROUBLESHOOTING....1837
POINTS TO REMEMBER WHEN TROUBLESHOOTING....1838
SEQUENCE OF EVENTS IN TROUBLESHOOTING....1839
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....1840
CHECKS BEFORE TROUBLESHOOTING....1848
CONNECTOR TYPES AND MOUNTING LOCATIONS....1850
CONNECTOR ARRANGEMENT DIAGRAM....1852
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....1864
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM....1888
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL....1891
TABLE OF MONITORING CODES....1896
TABLE OF SERVICE CODES....1909
TABLE 1 OF MONITORING CODES (ALL CODES)....1913
TABLE 2 OF MONITORING CODES (DETAILS OF BIT PATTERN CODE)....1914
METHOD OF USING JUDGEMENT TABLE....1921
METHOD OF USING TROUBLESHOOTING CHARTS....1925
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE....1929
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (n MODE)....1939
N-1(E218) COMMUNICATION ABNORMALITY....1940
TROUBLESHOOTING OF CUMMUNICATION ABNORMALITY SYSTEM (N MODE)....1943
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....1944
ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM....1946
N-1 [E117, E118 OCCUR AT SAME TIME] MONITOR PANEL COMMUNICATION ABNORMALITY....1947
N-2 [E117, E218 OCCUR AT SAME TIME] ENGINEER CONTROLLER COMMUNICATION ABNORMALITY....1949
N-3 [E118, E955 OCCUR AT SAME TIME] PUMP CONTROLLER COMMUNICATION ABNORMALITY....1951
TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM0, ENGING CONTROL SYSTEM (E MODE)....1953
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER SYSTEM....1954
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....1956
JUDGEMENT TABLE FOR ENGINE THROTTLE & PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS....1960
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM....1962
E-1 ABNORMALITY IN ENGINE THROTTLE & PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)....1964
E-2 [E308] (ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE) IS DISPLAYED....1965
E-3 [E317] (ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM) IS DISPLAYED....1966
E-4 [E318] (ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED....1967
E-5 [E306] (ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM) IS DISPLAYED....1968
E-6 [E315] (ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM) IS DISPLAYED....1969
E-7 [E316] (ABNORMALITY (STEP-0UT) IN MOTOR) IS DISPLAYED....1970
E-8 ENGINE SPEED IS IRREGULAR....1972
E-9 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)....1976
E-10 ENGINE DOES NOT START....1978
E-11 ENGINE DOES NOT STOP (DEFECT IN ENGINE STOP SOLENOID SYSTEM)....1981
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (MONITOR PANEL, CONTROLLER DO NOT STOP)....1982
E-13 ENGINE DOES NOT STOP....1984
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE)....1985
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED....1986
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS....1994
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM....1996
E-1 [E91b] (ABNORMALITY IN ENGINE SPEED NE SENSOR SYSTEM) IS DISPLAYED....1998
E-2 [E91C] (ABNORMALITY IN ENGINE G ROTATION SENSOR SYSTEM) IS DISPLAYED....1999
E-3 [E920] (ABNORMALITY IN MODEL SELECTION SYSTEM) IS DISPLAYED....2000
E-4 [E922] (ENGINE OVERRUN) IS DISPLAYED....2001
E-5 [E924] (DROP IN ENGINE OIL PRESSURE IS DISPLAYED....2002
E-6 [E931] (ABNORMALITY IN FUEL CONTROL DIAL SENSOR SYSTEM) IS DISPLAYED....2003
E-7 [E934] (ABNORMALITY IN ENGINE WATER TEMPERATURE 9HIGH) SENSOR SYSTEM) IS DISPLAYED....2004
E-8 [E936] (ABNORMALITY IN ENGINE OIL PRESSURE SWITCH SYSTEM) IS DISPLAYED....2005
E-9 [E93C] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM) IS DISPLAYED....2006
E-10 [E93d] 9ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED....2007
E-11 [E954] (SHORT CIRCUIT IN STARTING SWITCH C SYSTEM) IS DISPLAYED....2008
E-12 [E955] (ABNORMALITY IN NETWORK SYSTEM) IS DISPLAYED....2008
E-13 [E956] (POWER SOURCE SYSTEM ABNORMALITY 1) IS DISPLAYED....2009
E-14 [E957] (POWER SOURCE SYSTEM ABNORMALITY 2) IS DISPLAYED....2010
E-15 [E95A] (ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL) IS DISPLAYED....2011
E-16 [E96A} (ABNORMALITY IN ENGINE WATER TEMPERATURE (LOW) SENSOR SYSTEM) IS DISPLAYED....2012
E-17 [E970] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED....2013
E-18 [E971] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED....2014
E-19 [E974] (DISCONNECTION IN FUEL SUPPLY PUMP PCV 1 SYSTEM) IS DISPLAYED....2015
E-20 [E975] (DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED....2016
E-21 [E977] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM) IS DISPLAYED....2017
E-22 [E979] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1) IS DISPLAYED....2018
E-22 [E97A] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2) IS DISPLAYED....2018
E-23 [E97b] (FUEL SUPPLY PUMP NON-FORCE FEED 1) IS DISPLAYED....2019
E-23 [E97C] (FUEL SUPPLY PUMP NON-FORCE FEED 2) IS DISPLAYED....2019
E-24 [E97d] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE) IS DISPLAYED....2021
E-25 [E980] (DEFECTIVE ENGINE CONTROLLER) IS DISPLAYED....2021
E-26 [E981] (DISCONNECTION IN NO. 1 FUEL INJECTOR SYSTEM) IS DISPLAYED....2022
E-27 [E982] (DISCONNECTION IN NO. 2 FUEL INJECTOR SYSTEM) IS DISPLAYED....2023
E-28 [E983] (DISCONNECTION IN NO. 3 FUEL INJECTOR SYSTEM) IS DISPLAYED....2024
E-29 [E984] (DISCONNECTION IN NO. 4 FUEL INJECTOR SYSTEM) IS DISPLAYED....2025
E-30 [E985] (DISCONNECTION IN NO. 5 FUEL INJECTOR SYSTEM) IS DISPLAYED....2026
E-31 [E986] (DISCONNECTION IN NO. 6 FUEL INJECTOR SYSTEM) IS DISPLAYED....2027
E-32 [E98A] (SHORT CIRCUIT IN NO. 1, NO. 2, NO. 3 FUEL INJECTOR SYSTEM) IS DISPLAYED....2028
E-33 [E98b] (SHORT CIRCUIT IN NO. 3, NO. 4, NO. 5 FUEL INJECTOR SYSTEM,) IS DISPLAYED....2031
TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROL SYSTEM) (C MODE)....2035
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM....2036
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....2038
JUDGEMENT TABLE FOR ENGINE THROTTLE & PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS....2044
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE....2046
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)....2048
C-2 [E232] (SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED....2049
C-3 [E233] (DISCONNECTION IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED....2051
C-4 [E203] (SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED....2053
C-5 [E213] (DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM) IS DISPLAYED....2055
C-6 [E201] (SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED....2057
C-7 [E211] (DISCONNECTION IN C0 CANCEL SOLENOID SYSTEM) IS DISPLATED....2058
C-8 [E205] (SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED....2059
C-9 [E-215] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED....2060
C-10 [E206] (SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED....2061
C-11 [E216] (DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED....2062
C-12 [E311] (SHORT CIRCUIT IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED....2063
C-13 [E312] (DISCONNECTION IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED....2064
C-14 [E217] (MODEL SELECTION INPUT ERROR) IS DISPLAYED....2065
C-15 [E224] (ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED....2067
C-16 [E225] (ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED....2068
C-17 [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM) IS DISPLAYED....2069
C-18 [E227] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED....2070
C-19 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)....2071
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)....2073
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM....2074
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....2076
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS....2084
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM....2086
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)....2088
C-2 [E232] (SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED....2089
C-3 [E233] (DISCONNECTION IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED....2091
C-4 [E203] (SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED....2093
C-5 [E213] (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED....2095
C-6 [E201] (SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM) IS DISPLAYED....2097
C-7 [E211] (DISCONNECTION IN CO CANCEL SOLENOID SYSTEM) IS DISPLAYED....2098
C-8 [E204] (SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED....2099
C-9 [E214] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED....2100
C-10 [E206] (SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED....2101
C-11 [E-216] (DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED....2102
C-12 [E311] (SHORT CIRCUIT IN BUCKET CURL HI CANCELSOLENOID SYTEM) IS DISPLAYED....2103
C-13 [E312] (DISCONNECTION IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED....2104
C-14 [E-217] (MODEL SELECTION INPUT ERROR) IS DISPLAYED....2105
C-15 [E224] (ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED....2107
C-16 [E225] (ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED....2108
C-17 [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM) IS DISPLAYED....2109
C-18 [E227] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED....2110
C-19 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)....2111
C-20 [E207] SHORT CIRCUIT IN FLASHING LIGHT RELAY DRIVE SYSTEM IS DISPLAYED....2113
C-21 FLASHING LIGHT RELAY DOES NOT WORK....2114
C-22 [E231] ABNORMALITY (SHORT CIRCUIT) IN STEP LIGHT POWER SOURCE RETENTION RELAY OUTPUT SYSTEM IS DISPLAYED....2115
C-23 STEP LIGHT SWITCH DOES NOT WORK....2116
C-24 [E302] SHORT CIRCUIT IN STEP LIGHT RELAY DRIVE SYSTEM IS DISPLAYED....2117
C-25 STEP LIGHT DOES NOT LIGHT UP....2118
C-26 [E228] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED....2119
TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)....2121
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE....2122
F-1 BIT PATTERN 20-(1) (SWING OILS PRESSURE SWITCH) DOES NOT LIGHT UP....2124
F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2125
F-3 BIT PATTERN 20-3 (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2126
F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH ) DOES NOT LIGHT UP....2127
F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2128
F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2129
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2130
F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2131
F-9 BIT PATTERN 21-(2) (SERVICE VALVE OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2132
F-10 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP....2133
F-11 BIT PATTERN 22-(5) (KEROSENE MODE CONNECTION) DOES NOT LIGHT UP....2134
F-12 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP....2135
TROUBLESHOOTING OF PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)....2137
ELECTRICAL CIRCUIT DIAGRAM FOR F MOD....2138
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2140
F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2141
F-3 BIT PATTERN 20-(3) (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2142
F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2143
F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DIES NOT LIGHT UP....2144
F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2145
F-7 BIT PATTERN 21-(1) (BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP'....2146
F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2147
F-9 BIT PATTERN 21-(2) (SERVICE VALVE OIL PRESSURE SWITCH) DOES NOT LIGHT UP....2148
F-10 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP....2149
F-11 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP....2150
F-12 WHEN STEP LIGHT SWITCH IS ON, BIT PATTERN 24-(1) DOES NOT GO OUT....2151
F-13 WHEN HORN SWITCH IS ON, BIT PATTERN 24-(2) DOES NOT GO OUT....2152
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)....2153
TABLE OF FAILURE MODES AND CAUSES....2154
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)....2156
WORK EQUIPMENT IS SLOW OR LACKS POWER....2157
HYDRAULIC CIRCUIT DIAGRAM AFTER INTERCHANGING HOSES....2158
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER....2159
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS....2160
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE....2162
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)....2163
H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) IS SLOW OR LACKS PWOER....2164
H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)....2165
H-8 EXCESSIVE HYDRULIC DRIFT....2165
H-9 EXCESSIVE TIME LAG....2166
H-10 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION....2166
H-11 IN COMPOUND OPERATIONS WITH SWING, WORK EQUIPMENT SPEED IS SLOW....2167
H-12 IN COMPOUND OPERATIONS WITH BUCKET CURL, SWING AND OTHER WORK EQUIPMENT SPEEDS ARE SLOW....2167
H-13 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS....2167
H-14 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRVELOPERATIONS....2168
H-15 DEVIATION IS EXCESSIVE WHEN STARTING....2172
H-16 TRAVEL SPEED IS SLOW....2174
H-17 TRAVEL SPEED DOES NOT SWITCH....2175
H-18 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)....2175
H-19 DOES NOT SWING....2176
H-20 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR....2177
H-21 EXCESSIVE OVERRUN WHEN STOPPING SWING....2178
H-22 EXCESSIVE SHOCK WHEN STOPPING SWING....2179
H-23 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING....2179
H-24 EXCESSIVE HYDRAULIC DRIFT OF SWING....2180
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)....2181
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....2184
ELECTRICAL CIRCUIT DIGRAM FOR M MODE SYSTEM....2186
M-1 [E101] ABNORMALITY IN ERROR DATA) IS DISPLAYED....2188
M-1 [E-102] (ERROR IN CLOCK DATA) IS DISPLAYED....2188
M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED....2189
M-3 [E-104] (AIR CLEANER CLOGGING DETECTED) IS DISPLAYED....2190
M-4 [E-106] (DROP IN ENGINE OIL PRESSURE DETECTED) IS DISPLAYED ....2190
M-5 [E-108] (ENGINE WATER TEMPERATURE 105 DEG. C DETECTED) IS DISPLAYED....2191
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS....2192
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT....2194
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)....2194
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH....2195
M-10 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH....2198
M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP)....2200
M-12 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING)....2202
M-13 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND. CAUTION ITEMS FLASHES BUT BUZZER DOES NOT SOUND....2206
M-14 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS....2206
M-15 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)....2207
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE....2208
M-17 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)....2208
M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL....2209
M-19 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY....2209
M-20 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT graphic (SWING LOCK MONITOR) DOES NOT LIGHT UP....2210
M-21 SWING HOLDING BRAKE RELEASE SWITCH IS TURNED ON, BUT graphic (SWING LOCK MONITOR) DOES NOT FLASH....2210
M-22 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING....2211
M-23 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED....2211
M-24 DEFECTIVE FUEL LEVEL SENSOR SYSTEM....2212
M-25 DEFECTIVE COOLAND TEMPERATURE SENSOR SYSTEM....2213
M-26 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM....2214
M-27 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM....2215
M-28 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM....2216
M-29 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED (INCLUDE E112, E113)....2218
M-30 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED (INCLUDE E114)....2223
M-31 ELECTRIC GREASE GUN DOES NOT WORK....2225
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)....2227
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....2230
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM....2232
M-1 [E101] ABNORMALITY IN ERROR DATA ) OR [E102] (ABNORMALITY IN CLOCK DATA) IS DISPLAYED....2234
M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT SYSTEM) IS DISPLAYED....2235
M-3 [E-104] (AIR CLEANER CLOGGING DETECTION) IS DISPLAYED....2236
M-4 [E108] (ENGINE WATER TEMPERATURE 105 DEG. C) IS DISPLAYED....2236
M-5 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS....2237
M-6 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT....2239
M-7 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE....2239
M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH....2240
M-9 PREHEATING IS NOT BEING USED BUT PREHEATING DISPLAY MONITOR LAMP LIGHTS UP....2243
M-10 WHEN ENGINE IS STARTED, BASIC CHECK ITEMS FLASH....2244
M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH....2245
M-12 WHEN ENGINE IS STARTED, CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH....2246
M-13 OPERATION OF ALARM BUZZER IS NOT NORMAL....2250
M-14 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP....2252
M-15 ENGINE WATER TEMPERATURE DISPLAY IS NOT NORMAL....2253
M-16 FUEL LEVEL GAUGE DISPLAY IS NOT NORMAL....2254
M-17 SWING LOCK SWITCH IS TURNED ON BUT SWING LOCK MONITOR LAMP DOES NOT LIGHT UP....2256
M-18 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL (EMERGENCY), SWING LOCK MONITOR LAMP DOES NOT FLASH....2257
M-19 SERVICE METER DOES NOT GIVE NORMAL DISPLAY....2258
M-20 DEFECTIVE FUEL LEVEL SENSOR SYSTEM....2259
M-21 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM....2260
M-22 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM....2261
M-23 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM....2262
M-24 WIPER IS NOT ACTUATED WHEN WIPER SWITCH IS OPERATED OR WIPER IS ACTUATED WHEN WIPER SWITCH IS NOT OPERATED....2263
M-25 WINDOW WASHER IS NOT ACTUATED WHEN SWITCH IS OPERATED OR WINDOW WASHER IS ACTUATED WHEN SWITCH IS NOT OPERATED....2268
M-26 ELECTRIC GREASE GUN DOES NOT WORK (MACHINES EQUIPPED WITH ELECTRIC GREASE GUN)....2271
30 DISASSEMBLY AND ASSEMBLY....2273
METHOD OF USING MANUAL....2276
PRECAUTIONS WHEN CARRYING OUT OPERATION....2279
SPECIAL TOOL LIST....2281
SKETCHES OF SPECIAL TOOLS....2291
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY....2300
REMOVAL OF FUEL SUPPLY PUMP ASSEMBLY....2301
INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY....2303
REMOVAL OF FUEL INJECTOR ASSEMBLY....2304
INSTALLATION OF FUEL INJECTOR ASSEMBLY....2306
REMOVAL OF NOZZLE TIP....2308
INSTALLATION OF NOZZLE TIP....2309
REMOVAL OF ENGINE FRONT SEAL....2309
INSTALLATION OF ENGINE FRONT SEAL....2311
REMOVAL OF ENGINE REAR SEAL....2313
INSTALLATION OF ENGINE REAR SEAL....2314
REMOVAL OF CYLINDER HEAD ASSEMBLY....2318
INSTALLATION OF CYLINDER HEAD ASSEMBLY....2321
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY....2325
INSTALLATION OF RADIATOR, HYDRUALIC COOLER ASSEMBLY....2326
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY....2327
INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY....2328
REMOVAL OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY....2330
INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY....2333
REMOVAL OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY....2334
INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY....2337
REMOVAL OF PTO ASSEMBLY....2338
INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY....2338
DISASSEMBLY OF PTO ASSEMBLY....2339
ASSEMBLY OF PTO ASSEMBLY....2341
REMOVAL OF FUEL TANK ASSEMBLY....2343
INSTALLATION OF FUEL TANK....2343
REMOVAL OF FUEL TANK ASSEMBLY....2344
INSTALLATION OF FUEL TANK....2344
DISASSEMBLY OF FINAL DRIVE ASSEMBLY....2346
ASSEMBLY OF FINAL DRIVE ASSEMBLY....2352
REMOVAL OF REVOLVING FRAME ASSEMBLY....2360
INSTALLATION OF REVOLVING FRAME ASSEMBLY....2361
REMOVAL OF SWING MOTOR ASSEMBLY....2362
INSTALLATION OF SWING MOTOR ASSEMBLY....2362
DISASSEMBLY OF SWING MOTOR ASSEMBLY....2363
ASSEMBLY OF SWING MOTOR ASSEMBLY....2367
REMOVAL OF SWING MACHINERY ASSEMBLY....2375
INSTALLATION OF SWING MACHINERY ASSEMBLY....2375
DISASSEMBLY OF SWING MACHINERY ASSEMBLY....2376
ASSEMBLY OF SWING MACHINERY ASSEMBLY....2380
REMOVAL OF SWING CIRCLE ASSEMBLY....2385
INSTALLATION OF SWING CIRCLE ASSEMBLY....2385
REMOVAL OF TRACK SHOE ASSEMBLY....2386
INSTALLATION OF TRACK SHOE ASSEMBLY....2387
DISASSEMBLY OF ONE LINK IN FIELD....2388
ASSEMBLY OF ONE LINK IN FIELD....2390
REMOVAL OF IDLER, RECOIL SPRING ASSEMBLY....2392
INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY....2392
DISASSEMBLY OF IDLER ASSEMBLY....2393
ASSEMBLY OF IDLER ASSEMBLY....2395
DISASSEMBLY OF RECOIL SPRING ASSEMBLY....2397
ASSEMBLY OF RECOIL SPRING ASSEMBLY....2398
REMOVAL OF TRACK ROLLER ASSEMBLY....2399
INSTALLATION OF TRACK ROLLER ASSEMBLY....2399
DISASSEMBLY OF TRACK ROLLER ASSEMBLY....2400
ASSEMBLY OF TRACK ROLLER ASSEMBLY....2401
REMOVAL OF CARRIER ROLLER ASSEMBLY....2403
INSTALLATION OF CARRIER ROLLER ASSEMBLY....2403
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY....2404
ASSEMBLY OF CARRIER ROLLER ASSEMBLY....2405
REMOVAL OF HYDRAULIC TANK ASSEMBLY....2407
INSTALLATION OF HYDRAULIC TANK ASSEMBLY....2408
DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY....2410
ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY....2411
REMOVAL OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY....2412
INSTALLATION OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY....2413
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY....2414
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY....2416
REMOVAL OF NO. 1 AND NO. 2 PUMP ASSEMBLY....2418
INSTALLATION OF NO. 1 AND NO. 2 PUMP ASSEMBLY....2419
DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY....2420
ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY....2430
REMOVAL OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY....2446
INSTALLATION OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY....2446
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY....2447
INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY....2447
DISASSEMBLY OF CENTER SWIVEL JOING ASSEMBLY....2448
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY....2448
DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY....2449
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY....2450
DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY....2451
ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY....2452
REMOVAL OF BUCKET CYLINDER ASSEMBLY....2453
INSTALLATION OF BUCKET CYLINDER ASSEMBLY....2454
REMOVAL OF ARM CYLINDER ASSEMBLY....2455
INSTALLATION OF ARM CYLINDER ASSEMBLY....2456
REMOVAL OF BOOM CYLINDER ASSEMBLY....2457
INSTALLATION OF BOOM CYLINDER ASSEMBLY....2458
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY....2459
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY....2462
REMOVAL OF BUCKET ASSEMBLY....2466
INSTALLATION OF BUCKET ASSEMBLY....2467
REMOVAL OF ARM ASSEMBLY....2468
INSTALLATION OF ARM ASSEMBLY....2469
REMOVAL OF BOOM ASSEMBLY....2470
INSTALLATION OF BOOM ASSEMBLY....2471
REMOVAL OF OPERATOR'S CAB ASSEMBLY....2472
INSTALLATION OF OPERATOR'S CAB ASSEMBLY....2473
REMOVAL OF COUNTERWEIGHT ASSEMBLY....2474
INSTALLATION OF COUNTERWEIGHT ASSEMBLY....2474
40 MAINTENANCE STANDARD....2475
ENGINE MOUNT....2476
PTO....2477
SWING MACHINERY....2478
SWING CIRCLE....2480
FINAL DRIVE....2482
TRACK FRAME AND RECOIL SPRING....2484
IDLER....2486
CARRIER ROLLER....2488
TRACK ROLLER....2489
TRACK SHOE....2490
DOUBLE SHOE....2493
TRIPLE GROUSER SHOE....2494
HYDRAULIC PUMP....2495
CONTROL AND PTO LUBRICATION PUMP....2497
CONTROL VALVE....2498
SWING MOTOR....2505
TRAVEL MOTOR....2506
WORK EQUIPMENT - SWING PPC VALVE....2507
TRAVEL PPC VALVE....2508
SERVICE PPC VALVE....2509
SOLENOID VALVE....2510
CENTER SWIVEL JOINT....2511
BOOM HOLDING VALVE....2512
BOOM LOWER REGENERATION VALVE....2513
HYDRAULIC CYLINDER....2514
BACKHOE SPECIFICATION....2514
BOOM CYLINDER....2514
ARM CYLINDER....2514
BUCKET CYLINDER....2514
LOADING SHOVEL SPECIFICATION....2516
BOOM CYLINDER....2516
ARM CYLINDER....2516
BUCKET CYLINDER....2516
BOTTOM DUMP CYLINDER....2517
WORK EQUIPMENT....2518
BACKHOE SPECIFICATION....2518
LOADING SHOVEL SPECIFICATION....2520
DIMENSIONS OF WORK EQUIPMENT....2522
BACKHOE SPECIFICATION....2522
ARM....2522
BUCKET....2524
90 OTHERS....2527
HYDRAULIC CIRCUIT DIAGRAM (2/2)....2529
HYDRAULIC CIRCUIT DIAGRAM (1/2)....2534
HYDRAULIC CIRCUIT DIAGRAM (2/2)....2539
ELECTRIC CIRCUIT DIAGRAM (1/3)....2540
ELECTRIC CIRCUIT DIAGRAM (2/3)....2545
ELECTRIC CIRCUIT DIAGRAM (3/3)....2550
ELECTRIC CIRCUIT DIAGRAM (1/4)....2555
ELECTRIC CIRCUIT DIAGRAM (2/4)....2560
ELECTRIC CIRCUIT DIAGRAM (3/4)....2565
ELECTRIC CIRCUIT DIAGRAM (4/4)....2570
SEBM027100K - Hydraulic Excavator PC600LC-6 Shop Manual Supplement for Machines Built To Cold Weather Specifications (-50C) (use with SEBM017100 & revisions)....2576
SEBM031206 - Hydraulic Excavator PC600-7, PC600LC-7 Shop Manual....3342
COVER....3342
CONTENTS....3343
01 GENERAL....3370
SPECIFICATION DRAWINGS....3371
SPECIFICATIONS....3373
WEIGHT TABLE....3377
FUEL, COOLANT AND LUBRICANTS....3379
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD....3380
PARTS RELATED TO ENGINE....3381
PTO....3383
CONTROL AND PTO LUBRICATION PUMP....3385
RADIATOR, OIL COOLER....3386
POWER TRAIN....3387
FINAL DRIVE....3389
SPROCKET....3390
SWING CIRCLE....3394
SWING MACHINERY....3395
TRACK FRAME, RECOIL SPRING....3397
IDLER....3399
CARRIER ROLLER....3401
TRACK ROLLER....3402
TRACK SHOE....3403
HYDRAULIC PIPING DRAWING....3409
HYDRAULIC TANK, HYDRAULIC FILTER....3411
HYDRAULIC PUMP (PISTON PUMP)....3413
LINE OIL FILTER....3441
CONTROL VALVE....3442
SWING MOTOR....3461
CENTER SWIVEL JOINT....3470
TRAVEL MOTOR....3471
VALVE CONTROL....3482
WORK EQUIPMENT, SWING PPC VALVE....3483
TRAVEL PPC VALVE....3487
SERVICE PPC VALVE....3489
PPC ACCUMULATOR....3490
PPC SHUTTLE VALVE....3491
SOLENOID VALVE....3492
BOOM HOLDING VALVE....3497
BOOM LOWER REGENERATION VALVE....3501
HYDRAULIC CYLINDER....3504
WORK EQUIPMENT....3507
DIMENSIONS OF WORK EQUPMENT....3509
COUNTERWEIGHT REMOVER....3513
AIR CONDITIONER....3517
ENGINE CONTROL....3518
MACHINE CONTROL SYSTEM....3523
MONITOR SYSTEM....3548
SENSORS....3563
20 TESTING AND ADJUSTING....3567
STANDARD VALUE TABLE FOR ENGINE....3568
STANDARD VALUE TABLE FOR CHASSIS....3569
TESTING AND ADJUSTING....3578
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING....3579
MEASURING ENGINE SPEED....3581
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)....3582
MEASURING EXHAUST GAS TEMPERATURE....3583
MEASURING EXHAUST GAS COLOR....3584
ADJUSTING VALVE CLEARANCE....3585
MEASURING COMPRESSION PRESSURE....3586
MEASURING BLOW-BY PRESSURE....3588
MEASURING ENGINE OIL PRESSURE....3589
HANDLING EQUIPMENT IN FUEL CIRCUIT....3590
RELEASING REMAINING PRESSURE IN FUEL SYSTEM....3590
MEASURING FUEL PRESSURE....3591
BLEEDING AIR FROM FUEL CIRCUIT....3592
CHECK FOR LEAKAGE IN FUEL SYSTEM....3594
ADJUSTING ENGINE SPEED SENSOR....3595
TESTING AND ADJUSTING FAN BELT TENSION....3596
TESTING AND ADJUSTING ALTERNATOR BELT TENSION....3597
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION....3598
TESTING CLEARANCE OF SWING CIRCLE BEARING....3599
TESTING AND ADJUSTING TRACK SHOE TENSION....3600
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES....3601
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE....3606
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE....3608
TESTING SERVO PISTON STROKE....3614
MEASURING PPC VALVE OUTPUT PRESSURE....3615
MEASURING OUTLET PRESSURES OF SOLENOID VALVE AND PPC SHUTTLE VALVE....3619
ADJUSTING WORK EQUIPMENTSWING PPC VALVE....3625
TESTING AND ADJUSTING TRAVEL DEVIATION....3626
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT....3628
MEASURING OIL LEAKAGE ....3629
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....3633
BLEEDING AIR FROM EACH PART....3634
INSPECTION PROCEDURES FOR DIODE....3637
SPECIAL FUNCTION OF MONITOR PANEL....3638
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT....3665
PREPARATION WORK FOR TROUBLESHOOTING ELECTRICAL SYSTEM....3666
PM-CLINIC SERVICE....3668
UNDERCARRIAGE INSPECTION....3674
TROUBLESHOOTING....3675
POINTS TO REMEMBER WHEN TROUBLESHOOTING....3676
SEQUENCE OF EVENTS IN TROUBLESHOOTING....3677
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....3678
CHECKS BEFORE TROUBLESHOOTING....3686
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING....3687
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM....3691
TROUBLESHOOTING WHEN ERROR CODE (ELECTRICAL SYSTEM) AND FAILURE CODE (MECHANICAL SYSTEM) ARE DISPLAYED (DISPLAYED CODE)....3732
BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE....3734
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE....3736
ERROR CODE IN ELECTRICAL SYSTEM E112 (WIPER DRIVE (FOR) S/C)....3738
ERROR CODE IN ELECTRICAL SYSTEM E113 (WIPER DRIVE (REV) S/C)....3742
ERROR CODE IN ELECTRICAL SYSTEM E114 (WASHER DRIVE S/C)....3744
ERROR CODE IN ELECTRICAL SYSTEM E115 (WIPER WORKING ABNORMALITY)....3746
ERROR CODE IN ELECTRICAL SYSTEM E116 (WIPER PARKING ABNORMALITY)....3748
ERROR CODE IN ELECTRICAL SYSTEM E117 (ENG. CONTROLLER S-NET COMM. ERR.)....3752
ERROR CODE IN ELECTRICAL SYSTEM E118 (PUMP CONTROLLER S-NET COMM. ERR.)....3754
ERROR CODE IN ELECTRICAL SYSTEM E128 (MONITOR COMM. ABNORMALITY)....3756
ERROR CODE IN ELECTRICAL SYSTEM E201 (CO CANCEL SOL. S/C)....3758
ERROR CODE IN ELECTRICAL SYSTEM E203 (SWING BRAKE SOL. S/C)....3760
ERROR CODE IN ELECTRICAL SYSTEM E204 (2-STAGE RELIEF SOL. S/C)....3762
ERROR CODE IN ELECTRICAL SYSTEM E206 (TRAVEL SPEED SOL. S/C)....3764
ERROR CODE IN ELECTRICAL SYSTEM E207 (FLASH LIGHT RELAY S/C)....3766
ERROR CODE IN ELECTRICAL SYSTEM E211 (CO CANCEL SOL. DISC.)....3768
ERROR CODE IN ELECTRICAL SYSTEM E213 (SWING BRAKE SOL. DISC.)....3770
ERROR CODE IN ELECTRICAL SYSTEM E214 (2-STAGE RELIEF SOL. DISC.)....3772
ERROR CODE IN ELECTRICAL SYSTEM E216 (TRAVEL SPEED SOL. DISC.)....3774
ERROR CODE IN ELECTRICAL SYSTEM E217 (MODEL SELECTION ABNORMALITY)....3776
ERROR CODE IN ELECTRICAL SYSTEM E218 (S-NET COMM. DISC.)....3778
ERROR CODE IN ELECTRICAL SYSTEM E221 (TRAVEL ALARM S/C)....3780
ERROR CODE IN ELECTRICAL SYSTEM E224 (F PUMP P. SENSOR ABNORMALITY)....3782
ERROR CODE IN ELECTRICAL SYSTEM E225 (R PUMP P. SENSOR ABNORMALITY)....3784
ERROR CODE IN ELECTRICAL SYSTEM E226 (PRESS. SENSOR POWER ABNORMALITY)....3786
ERROR CODE IN ELECTRICAL SYSTEM E227 (ENGINE SPEED SENSOR ABNORMALITY)....3788
ERROR CODE IN ELECTRICAL SYSTEM E232 (TVC SOL. S/C)....3790
ERROR CODE IN ELECTRICAL SYSTEM E233 (TVC SOL. DISC.)....3792
ERROR CODE IN ELECTRICAL SYSTEM E257 (PUMP COMM. ABNORMALITY)....3794
ERROR CODE IN ELECTRICAL SYSTEM E302 (STEP LIGHT RELAY S/C)....3796
ERROR CODE IN ELECTRICAL SYSTEM E304 (STEP LIGHT POWER HOLD RELAY S/C)....3798
ERROR CODE IN ELECTRICAL SYSTEM E311 (BUCKET CURL HI CANCEL SOL. S/C)....3800
ERROR CODE IN ELECTRICAL SYSTEM E312 (BUCKET CURL HI CANCEL SOL. DISC.)....3802
ERROR CODE IN ELECTRICAL SYSTEM E315 (BATTERY RELAY DRIVE S/C)....3804
ERROR CODE IN ELECTRICAL SYSTEM E91B (ENGINE NE SENSOR PROBLEM)....3806
ERROR CODE IN ELECTRICAL SYSTEM E91C (ENGINE G SENSOR PROBLEM)....3807
ERROR CODE IN ELECTRICAL SYSTEM E920 (ENGINE TYPE SELECTION ERROR)....3808
ERROR CODE IN ELECTRICAL SYSTEM E921 (ENGINE TYPE MISMATCH)....3810
ERROR CODE IN ELECTRICAL SYSTEM E931 (FUEL DIAL SYS. ERROR)....3811
ERROR CODE IN ELECTRICAL SYSTEM E934 (ENGINE COOLANT SENSOR HI ERROR)....3813
ERROR CODE IN ELECTRICAL SYSTEM E936 (ENGINE OIL PRESS. SW. ERROR)....3815
ERROR CODE IN ELECTRICAL SYSTEM E93C (ENGINE BOOST SENSOR ERROR)....3817
ERROR CODE IN ELECTRICAL SYSTEM E93D (ENGINE FUEL TEMP. SENSOR ERROR)....3819
ERROR CODE IN ELECTRICAL SYSTEM E953 (ENGINE COMM. ABNORMALITY)....3821
ERROR CODE IN ELECTRICAL SYSTEM E954 (SHORT ENGINE STARTER SW.)....3823
ERROR CODE IN ELECTRICAL SYSTEM E955 (ENGINE S-NET ERROR)....3825
ERROR CODE IN ELECTRICAL SYSTEM E956 (ENGINE POWER FAILURE (1))....3827
ERROR CODE IN ELECTRICAL SYSTEM E957 (ENGINE POWER FAILURE (2))....3829
ERROR CODE IN ELECTRICAL SYSTEM E95A (ENGINE Q-ADJ. SW. SIGNAL ERROR)....3831
ERROR CODE IN ELECTRICAL SYSTEM E96A (ENGINE COOLANT SENSOR LO ERROR)....3832
ERROR CODE IN ELECTRICAL SYSTEM E970 (PCV1 OVER CURRENT)....3834
ERROR CODE IN ELECTRICAL SYSTEM E971 (PCV2 OVER CURRENT)....3836
ERROR CODE IN ELECTRICAL SYSTEM E974 (PCV1 LINE CUT)....3838
ERROR CODE IN ELECTRICAL SYSTEM E975 (PCV2 LINE CUT)....3840
ERROR CODE IN ELECTRICAL SYSTEM E977 (RAIL PRESS. SENSOR ERROR)....3842
ERROR CODE IN ELECTRICAL SYSTEM E979 (RAIL PRESS. HIGH)....3844
ERROR CODE IN ELECTRICAL SYSTEM E97A (RAIL PRESS. ABNORMAL)....3844
ERROR CODE IN ELECTRICAL SYSTEM E97B (RAIL PRESS. LOW)....3845
ERROR CODE IN ELECTRICAL SYSTEM E97C (RAIL PRESS. TOO LOW)....3847
ERROR CODE IN ELECTRICAL SYSTEM E97D (RAIL PRESS. OUT OF CONTROL)....3847
ERROR CODE IN ELECTRICAL SYSTEM E980 (ENG. CONTROLLER ABNORMALITY)....3848
ERROR CODE IN ELECTRICAL SYSTEM E981 (FUEL INJECTOR 1 DISC.)....3850
ERROR CODE IN ELECTRICAL SYSTEM E982 (FUEL INJECTOR 2 DISC.)....3851
ERROR CODE IN ELECTRICAL SYSTEM E983 (FUEL INJECTOR 3 DISC.)....3852
ERROR CODE IN ELECTRICAL SYSTEM E984 (FUEL INJECTOR 4 DISC.)....3853
ERROR CODE IN ELECTRICAL SYSTEM E985 (FUEL INJECTOR 5 DISC.)....3854
ERROR CODE IN ELECTRICAL SYSTEM E986 (FUEL INJECTOR 6 DISC.)....3855
ERROR CODE IN ELECTRICAL SYSTEM E98A (FUEL INJECTOR 1-3 S/C)....3856
ERROR CODE IN ELECTRICAL SYSTEM E98B (FUEL INJECTOR 4-6 S/C)....3858
FAILURE CODE IN MECHANICAL SYSTEM A000N1 (ENG. HI OUT OF STD)....3860
FAILURE CODE IN MECHANICAL SYSTEM AA10NX (AIRCLEANER CLOGGING)....3861
FAILURE CODE IN MECHANICAL SYSTEM AB00KE (CHARGE VOLTAGE LOW)....3863
FAILURE CODE IN MECHANICAL SYSTEM B@BAZG (ENG. OIL PRESS. LOW)....3865
FAILURE CODE IN MECHANICAL SYSTEM B@BAZK (ENG. OIL LEVEL LOW)....3867
FAILURE CODE IN MECHANICAL SYSTEM B@BCNS (ENG. WATER OVERHEAT)....3868
FAILURE CODE IN MECHANICAL SYSTEM B@BCZK (ENG. WATER LVL LOW)....3869
FAILURE CODE IN MECHANICAL SYSTEM B@HANS (HYDR. OIL OVERHEAT)....3871
FAILURE CODE IN MECHANICAL SYSTEM DA80MA (AUTO. LUB ABNORMAL)....3873
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)....3874
BEFORE CARRYING OUT TROUBLESHOOTING E MODE....3875
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE....3877
E-1 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)....3878
E-2 PREHEATER DOES NOT OPERATE....3881
E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK....3883
E-4 AUTO-DECELERATOR DOES NOT OPERATE....3884
E-5 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE....3885
E-6 ONE-TOUCH POWER MAX, FUNCTION DOES NOT OPERATE....3887
E-7 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY....3888
E-8 ANY ITEM IS NOT DISPLAYED ON MONITOR PANEL....3890
E-9 PART OF DISPLAY ON MONITOR PANEL IS MISSING....3891
E-10 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL....3891
E-11 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING....3892
E-12 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY....3893
E-13 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY....3895
E-14 FUEL GAUGE DOES NOT DISPLAY CORRECTLY....3896
E-15 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY....3897
E-16 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED....3899
E-17 WIPER AND WINDOW WASHER DO NOT WORK....3901
E-18 ALARM BUZZER CANNOT BE CANCELLED....3908
E-19 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION....3909
E-20 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION....3910
E-21 "ARM CURL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION....3911
E-22 "ARM DUMP" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION....3912
E-23 "BUCKET CURL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION....3913
E-24 "BUCKET DUMP" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION....3914
E-25 "SWING" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION....3915
E-26 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION....3917
E-27 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION....3919
E-28 AIR CONDITIONER DOES NOT WORK....3921
E-29 STEP LIGHT DOES NOT LIGHT UP OR GO OFF....3922
E-30 ELECTRIC GREASE GUN DOES NOT OPERATE....3926
E-31 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING....3928
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)....3930
BEFORE TROUBLESHOOTING H MODE....3931
INFORMATION IN TROUBLESHOOTING TABLE....3936
H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, TRAVEL, AND SWING IS LOW....3937
H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS....3939
H-3 ALL WORK EQUIPMENT, TRAVEL, AND SWING SYSTEMS DO NOT WORK....3940
H-4 ABNORMAL SOUND IS HEARD FROM AROUND PUMP....3941
H-5 AUTO-DECELERATOR IS NOT RESET....3942
H-6 BOOM SPEED OR POWER IS LOW....3943
H-7 ARM SPEED OR POWER IS LOW....3945
H-8 BUCKET SPEED OR POWER IS LOW....3946
H-9 BOOM DOES NOT MOVE....3947
H-10 ARM DOES NOT MOVE....3947
H-11 BUCKET DOES NOT MOVE....3947
H-12 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE....3948
H-13 TIME LAG OF WORK EQUIPMENT IS LARGE....3950
H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT OPERATE OR STOP....3951
H-15 HEAVY LIFT FUNCTION DOES NOT OPERATE OR STOP....3951
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE OR STOP....3951
H-17 WHEN ARM AND BOOMBUCKET ARE OPERATED SIMULTANEOUSLY, BOOMBUCKET SPEED IS LOW....3952
H-18 WHEN BUCKET AND BOOMARMSWINGTRAVEL ARE OPERATED SIMULTANEOUSLY, BOOMARMSWINGTRAVEL SPEED IS LOW....3952
H-19 WHEN ARM AND SWING ARE OPERATED SIMULTANEOUSLY, SWING SPEED IS LOW....3953
H-20 MACHINE DEVIATES IN ONE DIRECTION....3954
H-21 MACHINE DEVIATES LARGELY AT START....3956
H-22 TRAVEL DEVIATION IS LARGE DURING COMPOUND OPERATION....3957
H-23 TRAVEL SPEED OR POWER IS LOW....3958
H-24 MACHINE DOES NOT TRAVEL (ONLY ONE TRACK)....3959
H-25 TRAVEL SPEED DOES NOT CHANGE....3960
H-26 UPPER STRUCTURE DOES NOT SWING....3961
H-27 SWING SPEED OR ACCELERATION IS LOW....3962
H-28 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING....3963
H-29 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING ....3964
H-30 LARGE ABNORMAL SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING....3965
H-31 HYDRAULIC DRIFT OF SWING IS LARGE....3966
TROUBLESHOOTING OF ENGINE (S MODE)....3967
POINTS TO REMEMBER WHEN TROUBLESHOOTING....3968
METHOD OF USING TROUBLESHOOTING CHARTS....3969
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....3972
S-2 ENGINE DOES NOT START....3973
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)....3976
S-4 ENGINE STOPS DURING OPERATIONS....3977
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....3978
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)....3979
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)....3980
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)....3981
S-9 OIL BECOMES CONTAMINATED QUICKLY....3982
S-10 FUEL CONSUMPTION IS EXCESSIVE....3983
S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)....3984
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)....3985
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)....3986
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)....3987
S-15 ABNORMAL NOISE IS MADE....3988
S-16 VIBRATION IS EXCESSIVE....3989
30 DISASSEMBLY AND ASSEMBLY....3990
METHOD OF USING MANUAL....3992
PRECAUTIONS WHEN CARRYING OUT OPERATION....3994
SPECIAL TOOL LIST....3996
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY....4013
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY....4016
REMOVAL AND INSTALLATION OF NOZZLE TIP....4020
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL....4022
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL....4024
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY....4029
REMOVAL AND INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY....4035
REMOVAL AND INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY....4037
REMOVAL AND INSTALLATION OF PTO ASSEMBLY....4040
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY....4041
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY....4043
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY....4044
DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR ASSEMBLY....4056
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY....4071
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY....4072
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR ASSEMBLY....4073
REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY....4084
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY....4085
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY....4093
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY....4094
DISASSEMBLY AND ASSEMBLY OF ONE LINK IN FIELD....4096
REMOVAL AND INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY....4099
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY....4100
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY....4103
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY....4105
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY....4106
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY....4109
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY....4110
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY....4113
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY....4115
REMOVAL AND INSTALLATION OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY....4117
DISASSEMBLY AND ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY....4119
REMOVAL AND INSTALLATION OF NO.1 AND NO.2 PUMP ASSEMBLY....4123
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY....4125
REMOVAL AND INSTALLATION OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY....4145
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY....4146
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY....4147
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY....4148
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY....4150
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY....4152
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY....4154
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY....4156
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY....4158
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY....4163
REMOVAL AND INSTALLATION OF ARM ASSEMBLY....4165
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY....4167
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY....4170
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY....4171
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)....4172
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY....4181
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY....4187
90 OTHERS....4188
HYDRAULIC CIRCUIT DIAGRAM....4189
ELECTRICAL CIRCUIT DIAGRAM (1/5)....4190
ELECTRICAL CIRCUIT DIAGRAM (2/5)....4191
ELECTRICAL CIRCUIT DIAGRAM (3/5)....4192
ELECTRICAL CIRCUIT DIAGRAM (4/5)....4193
ELECTRICAL CIRCUIT DIAGRAM (5/5)....4194
ELECTRICAL CIRCUIT FOR AIR CONDITIONER....4195
SEN00128-16 - Hydraulic Excavator PC600-8, PC600LC-8 Shop Manual....4196
COVER....4196
00 Index and foreword....0
Index....4198
Composition of shop manual....4199
Table of contents....4201
Foreword and general information....4210
Safety notice....4211
How to read the shop manual....4216
Explanation of terms for maintenance standard....4218
Handling of electric equipment and hydraulic component....4220
Handling of connectors newly used for engines....4229
How to read electric wire code....4232
Precautions when carrying out operation....4235
Method of disassembling and connecting push-pull type coupler....4238
Standard tightening torque table....4241
Conversion table....4245
01 Specification....0
Specification and technical data....4252
Specification and technical data....4253
Specification drawings....4253
Working range drawings....4255
Specifications....4257
Weight table....4265
Table of fuel, coolant and lubricants....4269
10 Structure, function and maintenance standard....0
Engine and cooling system....4272
Engine and cooling system....4273
Parts related to engine....4273
PTO....4275
Fan, control and PTO lubrication pump....4277
Radiator, oil cooler....4278
Power train....4280
Power train....4281
Power train....4281
Final drive....4284
Sprocket....4287
Swing circle....4289
Swing machinery....4291
Undercarriage and frame....4294
Undercarriage and frame....4295
Track frame, recoil spring....4295
Idler....4297
Carrier roller....4299
Track roller....4300
Track shoe....4301
Hydraulic system, Part 1....4308
Hydraulic system, Part 1....4309
Hydraulic piping drawing....4309
Hydraulic tank, hydraulic filter....4311
Hydraulic pump (piston pump)....4313
Line oil filter....4341
Cooling fan pump....4343
Cooling fan motor....4351
Hydraulic system, Part 2....4358
Hydraulic system, Part 2....4359
Control valve....4359
Swing motor....4378
Swing brake....4381
Safety valve....4382
Reverse prevention valve....4384
Center swivel joint....4387
Travel motor....4388
Parking brake....4393
Brake valve....4395
Set pressures varying mechanism....4398
Valve control....4399
Work equipment, swing PPC valve....4401
Travel PPC valve....4405
Service PPC valve....4407
PPC accumulator....4408
PPC shuttle valve....4409
Solenoid valve....4410
Boom holding valve....4415
Boom LOWER regeneration valve....4419
Quick return valve....4422
Hydraulic cylinder....4425
Work equipment....4430
Work equipment....4431
Work equipment....4431
Dimensions of work equipment....4435
Cab and its attachments....4440
Cab and its attachments....4441
Air conditioner piping....4441
Electrical system....4443
Engine control....4444
Machine control system diagram....4449
Monitor system....4473
Sensors....4488
KOMTRAX system....4492
20 Standard value table....0
Standard service value table....4495
Standard value table for engine....4496
Standard value table for chassis....4497
30 Testing and adjusting....0
Testing and adjusting, Part 1....4519
Tools for testing, adjusting and troubleshooting....4522
Measuring engine speed....4527
Measuring intake air pressure (boost pressure)....4528
Measuring exhaust gas temperature....4529
Measuring exhaust gas color....4530
Adjusting valve clearance....4531
Measuring compression pressure....4532
Measuring blow-by pressure....4534
Measuring engine oil pressure....4534
Testing EGR valve and bypass valve drive oil pressure....4535
Handling equipment in fuel circuit....4536
Releasing remaining pressure in fuel system....4536
Measuring fuel pressure....4537
Reduced cylinder mode operation....4538
No-injection cranking....4538
Testing leakage from pressure limiter and return rate from injector....4539
Bleeding air from fuel circuit....4541
Testing fuel system for leakage....4543
Testing and adjusting alternator belt tension....4544
Testing and adjusting air conditioner compressor belt tension....4545
Testing clearance of swing circle bearing....4546
Testing and adjusting track shoe tension....4547
Testing and adjusting work equipment, swing, and travel circuit oil pressures....4548
Testing and adjusting control circuit oil pressure....4553
Testing and adjusting piston pump control oil pressure....4555
Testing servo piston stroke....4561
Measuring PPC valve output pressure....4562
Measuring outlet pressures of solenoid valve and PPC shuttle valve....4566
Adjusting work equipment, swing PPC valve....4572
Testing and adjusting travel deviation....4573
Measuring fan speed....4575
Measuring fan circuit oil pressure....4575
Inspection of locations of hydraulic drift of work equipment....4576
Measuring oil leakage....4577
Releasing remaining pressure in hydraulic circuit....4581
Bleeding air from each part....4582
Inspection procedures for diode....4585
Testing and adjusting, Part 2....4587
Special function of machine monitor....4588
Handling controller voltage circuit....4622
Procedure for turning on KOMTRAX terminal....4623
KOMTRAX terminal lamp indications....4626
Preparation work for troubleshooting electrical system....4629
Adjusting mirrors....4631
Pm-clinic service....4632
Undercarriage inspection....4638
40 Troubleshooting....0
Failure code table and fuse locations....4641
Failure codes table....4642
Fuse locations....4646
General information on troubleshooting....4649
Points to remember when troubleshooting....4650
Sequence of events in troubleshooting....4651
Checks before troubleshooting....4652
Classification and procedures of troubleshooting....4653
Information contained in troubleshooting table....4654
Failure-looking phenomenon and troubleshooting No....4656
Connection table for connector pin numbers....4660
T- branch box and T- branch adapter table....4696
Troubleshooting by failure code (Display of code), Part 1....4701
Failure code [A000N1] Eng. Hi Out of Std....4703
Failure code [AA10NX] Aircleaner clogging....4704
Failure code [AB00KE] Charge Voltage Low....4706
Failure code [B@BAZG] Eng. Oil Press. Low....4708
Failure code [B@BAZK] Eng. Oil Level Low....4710
Failure code [B@BCNS] Eng. Water Overheat....4711
Failure code [B@BCZK] Eng. Water Lvl Low....4712
Failure code [B@HANS] Hydr. Oil Overheat....4714
Failure code [CA111] ECM Critical Internal Failure....4715
Failure code [CA115] Eng Ne and Bkup Speed Sens Error....4716
Failure code [CA122] Chg Air Press Sensor High Error....4718
Failure code [CA123] Chg Air Press Sensor Low Error....4720
Failure code [CA131] Throttle Sensor High Error....4722
Failure code [CA132] Throttle Sensor Low Error....4724
Failure code [CA135] Eng Oil Press Sensor High Error....4726
Failure code [CA141] Eng Oil Press Sensor Low Error....4728
Failure code [CA144] Coolant Temp Sens High Error....4730
Failure code [CA145] Coolant Temp Sens Low Error....4732
Failure code [CA153] Chg Air Temp Sensor High Error....4734
Failure code [CA154] Chg Air Temp Sensor Low Error....4736
Failure code [CA187] Sens Supply 2 Volt Low Error....4736
Failure code [CA221] Ambient Press Sens High Error....4738
Failure code [CA222] Ambient Press Sens Low Error....4740
Failure code [CA227] Sens Supply 2 Volt High Error....4742
Failure code [CA234] Eng Overspeed....4744
Failure code [CA238] Ne Speed Sens Supply Volt Error....4745
Failure code [CA263] Fuel Temp Sensor High Error....4746
Failure code [CA265] Fuel Temp Sensor Low Error....4748
Failure code [CA271] IMV/PCV1 Short Error....4749
Failure code [CA272] IMV/PCV1 Open Error....4750
Failure code [CA273] PCV2 Short Error....4751
Failure code [CA274] PCV2 Open Error....4752
Troubleshooting by failure code (Display of code), Part 2....4755
Failure code [CA322] Inj #1 (L#1) Open/Short Error....4758
Failure code [CA323] Inj #5 (L#5) Open/Short Error....4760
Failure code [CA324] Inj #3 (L#3) Open/Short Error....4762
Failure code [CA325] Inj #6 (L#6) Open/Short Error....4764
Failure code [CA331] Inj #2 (L#2) Open/Short Error....4766
Failure code [CA332] Inj #4 (L#4) Open/Short Error....4768
Failure code [CA342] Calibration Code Incompatibility....4770
Failure code [CA351] Injectors Drive Circuit Error....4771
Failure code [CA352] Sens Supply 1 Volt Low Error....4773
Failure code [CA386] Sens Supply 1 Volt High Error....4774
Failure code [CA441] Battery Voltage Low Error....4776
Failure code [CA442] Battery Voltage High Error....4776
Failure code [CA449] Rail Press Very High Error....4777
Failure code [CA451] Rail Press Sensor High Error....4778
Failure code [CA452] Rail Press Sensor Low Error....4780
Failure code [CA553] Rail Press High Error....4780
Failure code [CA554] Rail Press Sensor In Range Error....4781
Failure code [CA559] Rail Press Low Error....4782
Failure code [CA689] Eng Ne Speed Sensor Error....4786
Failure code [CA731] Eng Bkup Speed Sens Phase Error....4788
Failure code [CA757] All Persistent Data Lost Error....4789
Failure code [CA778] Engine Bkup Speed Sensor Error....4790
Failure code [CA1228] EGR Valve Servo Error 1....4792
Failure code [CA1625] EGR Valve Servo Error 2....4793
Failure code [CA1626] BP Valve Sol Current High Error....4794
Failure code [CA1627] BP Valve Sol Current Low Error....4796
Failure code [CA1628] Bypass Valve Servo Error 1....4797
Failure code [CA1629] Bypass Valve Servo Error 2....4798
Failure code [CA1631] BP Valve Pos Sens High Error....4799
Failure code [CA1632] BP Valve Pos Sens Low Error....4801
Failure code [CA1633] KOMNET Datalink Timeout Error....4802
Failure code [CA1642] EGR Inlet Press Sens Low Error....4805
Failure code [CA1653] EGR Inlet Press Sens High Error....4806
Failure code [CA2185] Throt Sens Sup Volt High Error....4808
Failure code [CA2186] Throt Sens Sup Volt Low Error....4810
Failure code [CA2249] Rail Press Very Low Error....4811
Failure code [CA2271] EGR Valve Pos Sens High Error....4812
Failure code [CA2272] EGR Valve Pos Sens Low Error....4814
Failure code [CA2351] EGR Valve Sol Current High Error....4816
Failure code [CA2352] EGR Valve Sol Current Low Error....4818
Failure code [CA2555] Grid Htr Relay Volt Low Error....4819
Failure code [CA2556] Grid Htr Relay Volt High Error....4820
Troubleshooting by failure code (Display of code), Part 3....4823
Failure code [D110KB] Battery Relay Drive S/C....4826
Failure code [D163KB] Flash Light Relay S/C....4828
Failure code [D195KB] Step Light Relay S/C....4830
Failure code [DA25KP] Press. Sensor Power Abnormality....4832
Failure code [DA2SKQ] Model Selection Abnormality....4834
Failure code [DA80MA] Auto. Lub Abnormal....4836
Failure code [DA2RMC] Pump Comm. Abnormality....4838
Failure code [DAFRMC] Monitor Comm. Abnormality....4840
Failure code [DGE5KY] Ambi. Temp. Sensor S/C....4842
Failure code [DGE5KY] Ambi. Temp. Sensor S/C....4844
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C....4845
Failure code [DHPAMA] F pump P. Sensor Abnormality....4846
Failure code [DHPBMA] R pump P. Sensor Abnormality....4848
Failure code [DV20KB] Travel Alarm S/C....4850
Failure code [DW43KA] Travel Speed Sol. Disc....4852
Failure code [DW43KB] Travel Speed Sol. S/C....4854
Failure code [DW45KA] Swing Brake Sol. Disc....4856
Failure code [DW45KB] Swing Brake Sol. S/C....4858
Failure code [DW48KA] CO Cancel Sol. Disc....4860
Failure code [DW48KB] CO Cancel Sol. S/C....4862
Failure code [DW7BKA] Fan Reverse Sol. Disc....4864
Failure code [DW7BKB] Fan Reverse Sol. S/C....4865
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc....4866
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C....4868
Failure code [DWK0KA] 2-stage Relief Sol. Disc....4870
Failure code [DWK0KB] 2-stage Relief Sol. S/C....4872
Failure code [DX16KA] Fan Pump EPC Sol. Disc....4874
Failure code [DX16KB] Fan Pump EPC Sol. S/C....4876
Failure code [DXA0KA] TVC Sol. Disc....4878
Failure code [DXA0KB] TVC Sol. S/C....4880
Failure code [DY20KA] Wiper Working Abnormality....4882
Failure code [DY20MA] Wiper Parking Abnormality....4884
Failure code [DY2CKB] Washer Drive S/C....4888
Failure code [DY2DKB] Wiper Drive (For) S/C....4890
Failure code [DY2EKB] Wiper Drive (Rev) S/C....4894
Troubleshooting of electrical system (E-mode)....4895
E-1 Engine does not start (Engine does not rotate)....4897
E-2 Preheater does not operate....4900
E-3 Auto engine warm-up device does not work....4902
E-4 Auto-decelerator does not operate....4903
E-5 All work equipment, swing and travel do not move....4904
E-6 Power max. function does not operate....4906
E-7 Machine push-up function does not operate normally....4907
E-8 Any item is not displayed on machine monitor....4909
E-9 Part of display on machine monitor is missing....4910
E-10 Machine monitor displays contents irrelevant to the model....4910
E-11 Fuel level monitor red lamp lights up while engine is running....4911
E-12 Engine coolant temperature gauge does not display correctly....4912
E-13 Hydraulic oil temperature gauge does not display correctly....4914
E-14 Fuel gauge does not display correctly....4915
E-15 Swing lock monitor does not display correctly....4916
E-16 When monitor switch is operated, nothing is displayed....4918
E-17 Wiper and window washer do not work....4920
E-18 "Boom Raise" is not correctly displayed in monitoring function....4928
E-19 "Boom Lower" is not correctly displayed in monitoring function....4930
E-20 "Arm IN" is not correctly displayed in monitoring function....4932
E-21 "Arm OUT" is not correctly displayed in monitoring function....4933
E-22 "Bucket CURL" is not correctly displayed in monitoring function....4934
E-23 "Bucket DUMP" is not correctly displayed in monitoring function....4935
E-24 "Swing" is not correctly displayed in monitoring function....4936
E-25 "Travel" is not correctly displayed in monitoring function....4938
E-26 Air conditioner does not work....4940
E-27 Step light does not light up or go off....4942
E-28 Electric grease gun does not operate....4946
E-29 Travel alarm does not sound or does not stop sounding....4948
E-30 Horn does not sound....4950
E-31 Bottom dump does not move....4952
Troubleshooting of hydraulic and mechanical system (H-mode)....4955
Before troubleshooting H-mode....4957
Information in troubleshooting table....4962
H-1 Speed or power of all work equipment, travel, and swing is low....4964
H-2 Engine speed lowers remarkably or engine stalls....4966
H-3 All work equipment, travel, and swing systems do not work....4968
H-4 Abnormal sound is heard from around pump....4970
H-5 Auto-decelerator is not reset....4971
H-6 Boom speed or power is low....4972
H-7 Arm speed or power is low....4974
H-8 Bucket speed or power is low....4975
H-9 Boom does not move....4976
H-10 Arm does not move....4976
H-11 Bucket does not move....4977
H-12 Bottom dump does not move....4977
H-13 Hydraulic drift of work equipment is large....4978
H-14 Time lag of work equipment is large....4979
H-15 Power max. function does not operate or stop....4980
H-16 Machine push-up function does not operate or stop....4980
H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is low....4981
H-18 When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel speed is low....4981
H-19 When arm and swing are operated simultaneously, swing speed is low....4982
H-20 Machine deviates in one direction....4983
H-21 Machine deviates largely at start....4985
H-22 Travel deviation is large during compound operation....4986
H-23 Travel speed or power is low....4987
H-24 Machine does not travel (only one track)....4988
H-25 Travel speed does not change....4989
H-26 Upper structure does not swing....4990
H-27 Swing speed or acceleration is low....4991
H-28 Upper structure overruns excessively when it stops swinging....4992
H-29 Large shock is made when upper structure stops swinging....4993
H-30 Large abnormal sound is made when upper structure stops swinging....4994
H-31 Hydraulic drift of swing is large....4995
Troubleshooting of engine (S-mode)....4997
Method of using troubleshooting chart....4999
S-1 Starting performance is poor....5002
S-2 Engine does not start....5004
S-3 Engine does not pick up smoothly....5008
S-4 Engine stops during operations....5009
S-5 Engine does not rotate smoothly....5010
S-6 Engine lacks output (or lacks power)....5011
S-7 Exhaust smoke is black (incomplete combustion)....5012
S-8 Oil consumption is excessive (or exhaust smoke is blue)....5013
S-9 Oil becomes contaminated quickly....5014
S-10 Fuel consumption is excessive....5015
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....5016
S-12 Oil pressure drops....5017
S-13 Oil level rises (Entry of coolant or fuel)....5018
S-14 Coolant temperature becomes too high (overheating)....5020
S-15 Abnormal noise is made....5021
S-16 Vibration is excessive....5022
50 Disassembly and assembly....0
General information on disassembly and assembly....5025
How to read this manual....5026
Coating materials list....5028
Special tools list....5031
Sketches of special tools....5037
Engine and cooling system, Part 1....5045
Removal and installation of fuel supply pump assembly....5046
Removal and installation of cylinder head assembly....5052
Removal and installation of fuel injector assembly....5068
Removal and installation of engine front seal....5071
Removal and installation of engine rear seal....5075
Engine and cooling system, Part 2....5081
Removal and installation of engine, PTO and hydraulic pump assembly....5082
Removal and installation of radiator assembly....5089
Removal and installation of hydraulic oil cooler assembly....5091
Removal and installation of aftercooler assembly....5093
Removal and installation of fan motor assembly....5095
Removal and installation of fuel tank assembly....5099
Power train....5101
Removal and installation of PTO assembly....5102
Disassembly and assembly of PTO assembly....5104
Removal and installation of swing motor and swing machinery assembly....5107
Disassembly and assembly of swing machinery assembly....5108
Removal and installation of swing circle assembly....5115
Disassembly and assembly of final drive assembly....5116
Undercarriage and frame....5127
Removal and installation of track shoe assembly....5128
Disassembly and assembly of 1 link in field....5130
Removal and installation of idler, recoil spring assembly....5134
Disassembly and assembly of idler assembly....5135
Disassembly and assembly of recoil spring assembly....5138
Removal and installation of track roller assembly....5140
Disassembly and assembly of track roller assembly....5141
Removal and installation of carrier roller assembly....5144
Disassembly and assembly of carrier roller assembly....5145
Removal and installation of revolving frame assembly....5148
Removal and installation of counterweight assembly....5150
Removal and installation of counterweight remover assembly....5151
Hydraulic system....5155
Removal and installation of hydraulic tank assembly....5156
Removal and installation of hydraulic pump assembly....5158
Removal and installation of control valve and solenoid valve assembly....5161
Disassembly and assembly of control valve assembly....5163
Disassembly and assembly of main control valve assembly....5164
Removal and installation of swing motor assembly....5168
Removal and installation of center swivel joint assembly....5169
Disassembly and assembly of center swivel joint assembly....5170
Disassembly and assembly of work equipment PPC valve assembly....5172
Disassembly and assembly of travel PPC valve assembly....5174
Disassembly and assembly of hydraulic cylinder assembly....5177
Disassembly and assembly of grease gun assembly....5183
Work equipment....5185
Removal and installation of bucket cylinder assembly (Backhoe specification)....5186
Removal and installation of bucket cylinder assembly (Loading shovel specification)....5188
Removal and installation of arm cylinder assembly (Backhoe specification)....5190
Removal and installation of arm cylinder assembly (Loading shovel specification)....5192
Removal and installation of boom cylinder assembly (Backhoe specification)....5194
Removal and installation of boom cylinder assembly (Loading shovel specification)....5196
Removal and installation of bottom dump cylinder assembly (Loading shovel specification)....5198
Removal and installation of bucket assembly (Backhoe specification)....5199
Removal and installation of bucket assembly (Loading shovel specification)....5201
Removal and installation of arm assembly (Backhoe specification)....5202
Removal and installation of arm assembly (Loading shovel specification)....5204
Removal and installation of boom assembly (Backhoe specification)....5205
Removal and installation of boom assembly (Loading shovel specification)....5207
Removal and installation of work equipment (Backhoe specification)....5209
Removal and installation of work equipment (Loading shovel specification)....5211
Cab and its attachments....5215
Removal and installation of operators cab....5216
Removal and installation of operators cab glass (stuck glass)....5219
Removal and installation of front window assembly....5229
Electrical system....5235
Removal and installation of air conditioner unit assembly....5236
Removal and installation of engine controller assembly....5238
Removal and Installation of KOMTRAX terminal assembly....5240
Removal and installation of pump controller assembly....5240
Removal and installation of monitor assembly....5241
90 Diagrams and drawings....0
Hydraulic diagrams and drawings....5243
Hydraulic circuit diagram (1/4) (Backhoe specification)....5245
Hydraulic circuit diagram (2/4) (ATT specification)....5246
Hydraulic circuit diagram (3/4) (Loading shovel specification)....5247
Hydraulic circuit diagram (4/4) (Loading shovel specification)....5248
Electrical diagrams and drawings....5251
Electrical circuit diagram (1/6)....5253
Electrical circuit diagram (2/6)....5254
Electrical circuit diagram (3/6)....5255
Electrical circuit diagram (4/6)....5256
Electrical circuit diagram (5/6)....5257
Electrical circuit diagram (6/6)....5258
Connector arrangement diagram....5259
Electrical circuit diagram for air conditioner....5260
TEN00037-02 - Hydraulic Excavator PC600-7, PC600LC-7 Operation & Maintenance Manual....5263
COVER....5263
FOREWORD....5264
FOREWORD....5265
SAFETY INFORMATION....5268
INTRODUCTION....5270
DIRECTIONS OF MACHINE....5270
BREAKING-IN THE NEW MACHINE....5270
PRODUCT INFORMATION....5271
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....5271
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION....5271
SERVICE METER LOCATION....5272
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....5272
CONTENTS....5273
SAFETY....5276
SAFETY....5277
SAFETY LABELS....5279
LOCATION OF SAFETY LABELS....5280
SAFETY LABELS....5281
GENERAL PRECAUTIONS....5287
SAFETY MACHINE OPERATION....5295
STARTING ENGINE....5295
OPERATION....5297
TRANSPORTATION....5302
BATTERY....5304
TOWING....5306
LIFTING OBJECTS WITH BUCKET....5307
SAFETY MAINTENANCE INFORMATION....5308
OPERATION....5316
MACHINE VIEW ILLUSTRATIONS....5317
OVERALL MACHINE VIEW....5317
CONTROLS AND GAUGES....5318
DETAILED CONTROLS AND GAUGES....5320
MONITORING SYSTEM....5320
SWITCHES....5343
CONTROL LEVERS AND PEDALS....5350
SUN ROOF....5353
WINDSHIELD....5353
EMERGENCY EXIT FROM OPERATOR'S CAB....5358
DOOR LOCK....5358
CAP WITH LOCK....5359
HOT AND COOL BOX....5360
MAGAZINE BOX....5360
ASHTRAY....5361
AIR CONDITIONER CONTROLS....5362
RADIO....5376
AUXILIARY ELECTRIC POWER....5381
FUSE....5382
CIRCUIT BREAKER....5383
CONTROLLER....5383
TOOL BOX....5384
GREASE PUMP....5385
ACCUMULATOR....5388
MACHINE OPERATIONS AND CONTROLS....5390
BEFORE STARTING ENGINE....5390
STARTING ENGINE....5408
AFTER STARTING ENGINE....5413
STOPPING THE ENGINE....5421
MACHINE OPERATION....5422
STEERING THE MACHINE....5426
SWINGING....5428
WORK EQUIPMENT CONTROLS AND OPERATIONS....5429
WORKING MODE....5431
PROHIBITED OPERATIONS....5432
GENERAL OPERATION INFORMATION....5435
TRAVELING ON SLOPES....5437
ESCAPE FROM MUD....5439
RECOMMENDED APPLICATIONS....5440
BUCKET REPLACEMENT....5441
PARKING MACHINE....5443
CHECK AFTER SHUT OFF ENGINE....5444
LOCKING....5445
TRANSPORTATION....5446
PRECAUTIONS FOR TRANSPORTATION....5446
LIFTING MACHINE....5446
SHIPPING MACHINE INFORMATION....5448
TRANSPORTATION POSTURE....5449
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....5454
COLD WEATHER OPERATION....5456
COLD WEATHER OPERATION INFORMATION....5456
AFTER DAILY WORK COMPLETION....5459
AFTER COLD WEATHER SEASON....5459
LONG TERM STORAGE....5460
BEFORE STORAGE....5460
DURING STORAGE....5460
AFTER STORAGE....5460
STARTING MACHINE AFTER LONG-TERM STORAGE....5461
TROUBLES AND ACTIONS....5462
RUNNING OUT OF FUEL....5462
PHENOMENA THAT ARE NOT FAILURES....5463
TOWING THE MACHINE....5464
SEVERE JOB CONDITION....5464
DISCHARGED BATTERY....5465
OTHER TROUBLE....5469
MAINTENANCE....5476
MAINTENANCE INFORMATION....5477
OUTLINE OF SERVICE....5479
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....5479
ELECTRIC SYSTEM MAINTENANCE....5481
WEAR PARTS....5482
WEAR PARTS LIST....5482
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS....5483
TIGHTENING TORQUE SPECIFICATIONS....5487
TIGHTENING TORQUE LIST....5487
SAFETY CRITICAL PARTS....5488
SAFETY CRITICAL PARTS LIST....5489
MAINTENANCE SCHEDULE....5490
MAINTENANCE SCHEDULE CHART....5490
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....5492
MAINTENANCE PROCEDURE....5493
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)....5493
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)....5493
WHEN REQUIRED....5494
CHECK BEFORE STARTING....5517
EVERY 10 HOURS MAINTENANCE....5518
EVERY 100 HOURS MAINTENANCE....5521
EVERY 250 HOURS MAINTENANCE....5522
EVERY 500 HOURS MAINTENANCE....5529
EVERY 1000 HOURS MAINTENANCE....5541
EVERY 2000 HOURS MAINTENANCE....5550
EVERY 4000 HOURS MAINTENANCE....5553
EVERY 5000 HOURS MAINTENANCE....5556
EVERY 8000 HOURS MAINTENANCE....5558
SPECIFICATIONS....5560
SPECIFICATIONS....5561
ATTACHMENTS, OPTIONS....5564
GENERAL PRECAUTIONS FOR SAFETY....5565
PRECAUTIONS WHEN SELECTING....5565
READ THE INSTRUCTION MANUAL THOROUGHLY....5565
PRECAUTIONS WHEN REMOVING OR INSTALLING....5565
PRECAUTIONS WHEN USING....5565
ATTACHMENT GUIDE....5566
COMBINATIONS OF WORK EQUIPMENT....5566
TRACK SHOES SELECTION....5569
HANDLING COUNTERWEIGHT REMOVER....5570
INDEX....5580
TEN00118-07 - Hydraulic Excavator PC600-8, PC600LC-8 Operation & Maintenance Manual....5584
COVER....5584
FOREWORD....5585
BEFORE READING THIS MANUAL....5586
SAFETY INFORMATION....5587
INTRODUCTION....5588
USE OF MACHINE....5588
DIRECTIONS OF MACHINE....5588
VISIBILITY FROM OPERATOR'S SEAT....5589
PRODUCT INFORMATION....5590
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....5590
EPA REGULATIONS, ENGINE NUMBER PLATE....5590
SERVICE METER LOCATION....5591
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....5591
CONTENTS....5592
SAFETY....5597
SAFETY....5598
SAFETY LABELS....5601
LOCATION OF SAFETY LABELS....5602
SAFETY LABELS....5603
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....5609
PRECAUTIONS BEFORE STARTING OPERATION....5609
PREPARATIONS FOR SAFE OPERATION....5609
FIRE PREVENTION....5611
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....5612
DO NOT GET CAUGHT IN WORK EQUIPMENT....5614
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....5614
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS....5614
UNAUTHORIZED MODIFICATION....5615
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....5615
PRECAUTIONS RELATED TO CAB GLASS....5615
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....5615
PRECAUTIONS FOR OPERATION....5616
PRECAUTIONS FOR JOBSITE....5616
STARTING ENGINE....5618
OPERATION....5620
TRANSPORTATION....5627
TOWING....5628
LIFTING OBJECTS WITH BUCKET....5629
PRECAUTIONS FOR MAINTENANCE....5630
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....5630
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....5634
OPERATION....5641
MACHINE VIEW ILLUSTRATIONS....5642
OVERALL MACHINE VIEW....5642
CONTROLS AND GAUGES....5643
DETAILED CONTROLS AND GAUGES....5645
MONITORING SYSTEM....5645
SWITCHES....5674
CONTROL LEVERS AND PEDALS....5681
SUN ROOF....5684
WINDSHIELD....5684
EMERGENCY EXIT FROM OPERATOR'S CAB....5689
DOOR LOCK....5689
CAP WITH LOCK....5690
HOT AND COOL BOX....5691
MAGAZINE BOX....5692
ASHTRAY....5692
FIRE EXTINGUISHER....5693
AIR CONDITIONER CONTROLS....5694
RADIO....5708
AUXILIARY ELECTRIC POWER....5712
FUSE....5713
CIRCUIT BREAKER....5714
CONTROLLER....5715
TOOL BOX....5715
GREASE PUMP....5716
MACHINE OPERATIONS AND CONTROLS....5719
BEFORE STARTING ENGINE....5719
STARTING ENGINE....5738
AFTER STARTING ENGINE....5741
STOPPING THE ENGINE....5750
MACHINE OPERATION....5751
STEERING THE MACHINE....5755
SWINGING....5757
WORK EQUIPMENT CONTROLS AND OPERATIONS....5758
WORKING MODE....5760
PROHIBITED OPERATIONS....5761
GENERAL OPERATION INFORMATION....5766
TRAVELING ON SLOPES....5768
ESCAPE FROM MUD....5770
RECOMMENDED APPLICATIONS....5771
BUCKET REPLACEMENT....5772
PARKING MACHINE....5774
MACHINE INSPECTION AFTER DAILY WORK....5775
LOCKING....5776
TRANSPORTATION....5777
PRECAUTIONS FOR TRANSPORTATION....5777
LIFTING MACHINE....5777
SHIPPING MACHINE INFORMATION....5779
TRANSPORTATION POSTURE....5780
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....5785
COLD WEATHER OPERATION....5787
COLD WEATHER OPERATION INFORMATION....5787
AFTER DAILY WORK COMPLETION....5790
AFTER COLD WEATHER SEASON....5790
LONG TERM STORAGE....5791
BEFORE STORAGE....5791
DURING STORAGE....5791
AFTER STORAGE....5792
STARTING MACHINE AFTER LONG-TERM STORAGE....5792
TROUBLES AND ACTIONS....5793
RUNNING OUT OF FUEL....5793
PHENOMENA THAT ARE NOT FAILURES....5794
TOWING THE MACHINE....5795
SEVERE JOB CONDITION....5795
DISCHARGED BATTERY....5796
OTHER TROUBLE....5800
MAINTENANCE....5807
MAINTENANCE INFORMATION....5808
OUTLINE OF SERVICE....5810
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....5810
ELECTRIC SYSTEM MAINTENANCE....5813
WEAR PARTS....5814
WEAR PARTS LIST....5814
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....5815
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....5817
TIGHTENING TORQUE SPECIFICATIONS....5818
TIGHTENING TORQUE LIST....5818
SAFETY CRITICAL PARTS....5819
SAFETY CRITICAL PARTS LIST....5820
MAINTENANCE SCHEDULE....5821
MAINTENANCE SCHEDULE CHART....5821
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....5823
MAINTENANCE PROCEDURE....5824
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)....5824
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)....5824
WHEN REQUIRED....5825
CHECK BEFORE STARTING....5849
EVERY 10 HOURS MAINTENANCE....5850
EVERY 100 HOURS MAINTENANCE....5852
EVERY 250 HOURS MAINTENANCE....5853
EVERY 500 HOURS MAINTENANCE....5859
EVERY 1000 HOURS MAINTENANCE....5869
EVERY 2000 HOURS MAINTENANCE....5881
EVERY 4000 HOURS MAINTENANCE....5887
EVERY 5000 HOURS MAINTENANCE....5890
EVERY 8000 HOURS MAINTENANCE....5891
SPECIFICATIONS....5893
SPECIFICATIONS....5894
ATTACHMENTS, OPTIONS....5897
GENERAL PRECAUTIONS FOR SAFETY....5898
PRECAUTIONS WHEN SELECTING....5898
READ THE INSTRUCTION MANUAL THOROUGHLY....5898
PRECAUTIONS WHEN REMOVING OR INSTALLING....5898
PRECAUTIONS WHEN USING....5898
ATTACHMENT GUIDE....5899
COMBINATIONS OF WORK EQUIPMENT....5899
TRACK SHOES SELECTION....5901
HANDLING COUNTERWEIGHT REMOVER....5902
HANDLING MACHINES EQUIPPED WITH KOMTRAX....5911
BASIC PRECAUTIONS....5911
LOADING SHOVEL....5913
EXPLANATION OF COMPONENTS....5914
SWITCHES....5914
FUSE....5917
OPERATIONS....5918
OPERATION OF WORK EQUIPMENT....5918
PRECAUTIONS DURING OPERATION....5920
PRECAUTIONS FOR JOBSITE....5923
EXCAVATOR WORK....5925
TRANSPORTATION....5926
MACHINE CONFIGURATION FOR TRANSPORT....5926
WEAR PARTS....5927
WEAR PARTS LIST....5927
MAINTENANCE....5928
CHECK BEFORE STARTING....5928
EVERY 10 HOURS MAINTENANCE....5930
EVERY 5000 HOURS MAINTENANCE....5931
SPECIFICATION....5932
COMBINATION OF WORK EQUIPMENT....5933
COMBINATION OF WORK EQUIPMENT....5933
INDEX....5935
TEN00346-02 - Hydraulic Excavator PC600-8, PC600LC-8 Operation & Maintenance Manual....5939
COVER....5939
FOREWORD....5940
BEFORE READING THIS MANUAL....5941
SAFETY INFORMATION....5942
INTRODUCTION....5943
USE OF MACHINE....5943
DIRECTIONS OF MACHINE....5943
VISIBILITY FROM OPERATOR'S SEAT....5944
PRODUCT INFORMATION....5945
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....5945
EPA REGULATIONS, ENGINE NUMBER PLATE....5945
SERVICE METER LOCATION....5946
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....5946
CONTENTS....5947
SAFETY....5952
SAFETY....5953
SAFETY LABELS....5956
LOCATION OF SAFETY LABELS....5957
SAFETY LABELS....5958
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....5964
PRECAUTIONS BEFORE STARTING OPERATION....5964
PREPARATIONS FOR SAFE OPERATION....5964
FIRE PREVENTION....5966
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....5967
DO NOT GET CAUGHT IN WORK EQUIPMENT....5969
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....5969
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS....5970
UNAUTHORIZED MODIFICATION....5971
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....5971
PRECAUTIONS RELATED TO CAB GLASS....5971
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....5971
PRECAUTIONS FOR OPERATION....5972
PRECAUTIONS FOR JOBSITE....5972
STARTING ENGINE....5974
OPERATION....5976
TRANSPORTATION....5983
TOWING....5984
LIFTING OBJECTS WITH BUCKET....5985
PRECAUTIONS FOR MAINTENANCE....5986
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....5986
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....5990
OPERATION....5996
MACHINE VIEW ILLUSTRATIONS....5997
OVERALL MACHINE VIEW....5997
CONTROLS AND GAUGES....5998
DETAILED CONTROLS AND GAUGES....6000
MONITORING SYSTEM....6000
SWITCHES....6029
CONTROL LEVERS AND PEDALS....6036
SUN ROOF....6039
WINDSHIELD....6039
EMERGENCY EXIT FROM OPERATOR'S CAB....6044
DOOR LOCK....6044
CAP WITH LOCK....6045
HOT AND COOL BOX....6046
MAGAZINE BOX....6047
ASHTRAY....6047
FIRE EXTINGUISHER....6048
AIR CONDITIONER CONTROLS....6049
RADIO....6063
AUXILIARY ELECTRIC POWER....6067
FUSE....6068
CIRCUIT BREAKER....6069
CONTROLLER....6070
TOOL BOX....6070
GREASE PUMP....6071
MACHINE OPERATIONS AND CONTROLS....6074
BEFORE STARTING ENGINE....6074
STARTING ENGINE....6093
AFTER STARTING ENGINE....6096
STOPPING THE ENGINE....6105
MACHINE OPERATION....6106
STEERING THE MACHINE....6110
SWINGING....6112
WORK EQUIPMENT CONTROLS AND OPERATIONS....6113
WORKING MODE....6115
PROHIBITED OPERATIONS....6116
GENERAL OPERATION INFORMATION....6121
TRAVELING ON SLOPES....6123
ESCAPE FROM MUD....6125
RECOMMENDED APPLICATIONS....6126
BUCKET REPLACEMENT....6127
PARKING MACHINE....6129
MACHINE INSPECTION AFTER DAILY WORK....6130
LOCKING....6131
TRANSPORTATION....6132
PRECAUTIONS FOR TRANSPORTATION....6132
LIFTING MACHINE....6132
SHIPPING MACHINE INFORMATION....6134
TRANSPORTATION POSTURE....6135
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....6140
COLD WEATHER OPERATION....6142
COLD WEATHER OPERATION INFORMATION....6142
AFTER DAILY WORK COMPLETION....6145
AFTER COLD WEATHER SEASON....6145
LONG TERM STORAGE....6146
BEFORE STORAGE....6146
DURING STORAGE....6146
AFTER STORAGE....6147
STARTING MACHINE AFTER LONG-TERM STORAGE....6147
TROUBLES AND ACTIONS....6148
RUNNING OUT OF FUEL....6148
PHENOMENA THAT ARE NOT FAILURES....6149
TOWING THE MACHINE....6150
SEVERE JOB CONDITION....6150
DISCHARGED BATTERY....6151
OTHER TROUBLE....6155
MAINTENANCE....6162
MAINTENANCE INFORMATION....6163
OUTLINE OF SERVICE....6165
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....6165
ELECTRIC SYSTEM MAINTENANCE....6168
WEAR PARTS....6169
WEAR PARTS LIST....6169
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....6170
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....6172
TIGHTENING TORQUE SPECIFICATIONS....6173
TIGHTENING TORQUE LIST....6173
SAFETY CRITICAL PARTS....6174
SAFETY CRITICAL PARTS LIST....6175
MAINTENANCE SCHEDULE....6176
MAINTENANCE SCHEDULE CHART....6176
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....6178
MAINTENANCE PROCEDURE....6179
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)....6179
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)....6179
WHEN REQUIRED....6180
CHECK BEFORE STARTING....6203
EVERY 10 HOURS MAINTENANCE....6204
EVERY 100 HOURS MAINTENANCE....6206
EVERY 250 HOURS MAINTENANCE....6207
EVERY 500 HOURS MAINTENANCE....6213
EVERY 1000 HOURS MAINTENANCE....6223
EVERY 2000 HOURS MAINTENANCE....6234
EVERY 4000 HOURS MAINTENANCE....6240
EVERY 5000 HOURS MAINTENANCE....6243
EVERY 8000 HOURS MAINTENANCE....6244
SPECIFICATIONS....6246
SPECIFICATIONS....6247
ATTACHMENTS, OPTAIONS....6250
GENERAL PRECAUTIONS FOR SAFETY....6251
PRECAUTIONS WHEN SELECTING....6251
READ THE INSTRUCTION MANUAL THOROUGHLY....6251
PRECAUTIONS WHEN REMOVING OR INSTALLING....6251
PRECAUTIONS WHEN USING....6251
ATTACHMENT GUIDE....6252
COMBINATIONS OF WORK EQUIPMENT....6252
TRACK SHOES SELECTION....6254
HANDLING COUNTERWEIGHT REMOVER....6255
HANDLING MACHINES EQUIPPED WITH KOMTRAX....6264
BASIC PRECAUTIONS....6264
LOADING SHOVEL....6266
EXPLANATION OF COMPONENTS....6267
SWITCHES....6267
FUSE....6270
OPERATIONS....6271
OPERATION OF WORK EQUIPMENT....6271
PRECAUTIONS DURING OPERATION....6273
PRECAUTIONS FOR JOBSITE....6276
EXCAVATOR WORK....6278
TRANSPORTATION....6279
MACHINE CONFIGURATION FOR TRANSPORT....6279
WEAR PARTS....6280
WEAR PARTS LIST....6280
MAINTENANCE....6281
CHECK BEFORE STARTING....6281
EVERY 10 HOURS MAINTENANCE....6283
EVERY 5000 HOURS MAINTENANCE....6284
SPECIFICATION....6285
COMBINATION OF WORK EQUIPMENT....6286
COMBINATION OF WORK EQUIPMENT....6286
INDEX....6288
UEAM005000 - Hydraulic Excavator PC600-8, PC600LC-8 Operation & Maintenance Manual....6292
FOREWORD....6295
SAFETY INFORMATION....6296
Signal words....6296
Example of safety message using signal word....6296
Other signal words....6296
Example of safety label using words....6297
Safety labels using pictogram....6297
NOISE....6298
Vibration levels....6299
Operating condition:....6299
Guide to Reduce Vibration Levels on Machine....6299
INTRODUCTION....6301
DIRECTIONS OF MACHINE....6301
VISIBILITY FROM OPERATOR'S SEAT....6302
PROXIMITY VISIBILITY....6302
12M CIRCUMFERENCE VISIBILITY....6302
BREAKING-IN THE NEW MACHINE....6303
PRODUCT INFORMATION....6304
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....6304
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION....6304
SERVICE METER LOCATION....6305
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....6305
MACHINE SERIAL PLATE....6306
FOREWORD....6307
SAFETY....6307
OPERATION....6308
MAINTENANCE....6310
SPECIFICATIONS....6312
ATTACHMENTS AND OPTIONS....6313
INDEX....6313
COLOPHON....6313
SAFETY INFORMATION....6315
SAFETY LABELS....6317
LOCATION OF SAFETY LABELS....6318
SAFETY LABELS....6319
SAFETY INFORMATION....6326
SAFETY RULES....6326
IF PROBLEMS ARE FOUND....6326
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS....6326
FIRE EXTINGUISHER AND FIRST AID KIT....6326
SAFETY EQUIPMENT....6327
KEEP MACHINE CLEAN....6327
KEEP OPERATOR'S COMPARTMENT CLEAN....6327
LEAVING OPERATOR'S SEAT WITH LOCK....6327
HANDRAILS AND STEPS....6328
MOUNTING AND DISMOUNTING....6329
NO PERSONS ON ATTACHMENTS....6329
DO NOT GET CAUGHT IN ARTICULATED PORTION....6329
BURN PREVENTION....6329
FIRE PREVENTION AND EXPLOSION PREVENTION....6330
ACTION IF FIRE OCCURS....6331
WINDSHIELD WASHER FLUID....6331
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION....6331
ATTACHMENT INSTALLATION....6331
ATTACHMENT COMBINATIONS....6331
CAB WINDOW GLASSES....6332
UNAUTHORIZED MODIFICATIONS....6332
SAFETY AT JOBSITE....6332
WORKING ON LOOSE GROUND....6332
DISTANCE TO HIGH VOLTAGE CABLES....6333
ENSURE GOOD VISIBILITY....6333
VENTILATION FOR ENCLOSED AREA....6334
SIGNALMAN'S SIGNAL AND SIGNS....6334
EMERGENCY EXIT FROM OPERATOR'S CAB....6334
ASBESTOS DUST HAZARD PREVENTION....6334
SAFETY MACHINE OPERATION....6335
STARTING ENGINE....6335
CHECKS BEFORE STARTING ENGINE....6335
SAFETY RULES FOR STARTING ENGINE....6336
STARTING ENGINE IN COLD WEATHER....6336
OPERATION....6337
CHECKS BEFORE OPERATION....6337
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS....6337
SAFETY RULES FOR TRAVELING....6338
TRAVELING ON SLOPES....6338
OPERATIONS ON SLOPES....6339
PROHIBITED OPERATIONS....6339
OPERATIONS ON SNOW....6341
PARKING MACHINE....6342
TRANSPORTATION....6343
LOADING AND UNLOADING....6343
SHIPPING THE MACHINE....6343
BATTERY....6344
BATTERY HAZARD PREVENTION....6344
STARTING ENGINE WITH BOOSTER CABLES....6345
TOWING....6345
SAFETY RULES FOR TOWING....6345
LIFTING OBJECTS WITH BUCKET....6346
SAFETY RULES FOR LIFTING OBJECTS....6346
SAFETY MAINTENANCE INFORMATION....6347
WARNING TAG....6347
KEEP WORK PLACE CLEAN AND TIDY....6347
APPOINT LEADER WHEN WORKING WITH OTHERS....6347
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE....6348
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....6348
PROPER TOOLS....6349
ACCUMULATOR....6349
PERSONNEL....6349
ATTACHMENTS....6350
WORK UNDER THE MACHINE....6350
NOISE....6350
WHEN USING HAMMER....6350
WELDING WORKS....6350
REMOVING BATTERY TERMINALS....6351
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION....6351
DO NOT DISASSEMBLE RECOIL SPRINGS....6351
SAFETY RULES FOR HIGH-PRESSURE OIL....6351
PRECAUTION FOR HIGH FUEL PRESSURE....6352
SAFETY HANDLING HIGH-PRESSURE HOSES....6352
PRECAUTION FOR HIGH VOLTAGE....6352
WASTE MATERIALS....6353
AIR CONDITIONER MAINTENANCE....6353
COMPRESSED AIR....6353
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....6353
MACHINE VIEW ILLUSTRATIONS....6355
OVERALL MACHINE VIEW....6355
CONTROLS AND GAUGES....6356
DETAILED CONTROLS AND GAUGES....6358
MONITORING SYSTEM....6358
Basic Operation of Machine Monitor....6359
If There Is Abnormality When Starting Engine....6359
If Any Abnormality Occurs During Operation....6360
Emergency Monitors....6362
Engine Coolant Temperature Monitor....6362
Hydraulic Oil Temperature Monitor....6363
Engine Oil Pressure Monitor....6363
Caution Monitors....6364
Charge Level Monitor....6364
Fuel Level Monitor....6365
Air Cleaner Clogging Monitor....6365
Engine Coolant Temperature Monitor....6365
Hydraulic Oil Temperature Monitor....6365
Basic Check Monitors....6366
Radiator Coolant Level Monitor....6366
Engine Oil Level Monitor....6367
Maintenance Interval Monitor....6367
Meter Display Portion....6368
Pilot Display....6368
Engine Pre-heating Monitor....6368
Swing Lock Monitor....6369
Wiper Monitor....6369
Auto-deceleration Monitor....6369
Working Mode Monitor....6369
Travel Speed Monitor....6370
One-Touch Power Max. Monitor....6370
Gauges and Meter....6371
Engine Coolant Temperature Gauge....6371
Fuel Gauge....6371
Hydraulic Oil Temperature Gauge....6372
Service Meter....6372
Monitor Switches Portion....6373
Working Mode Selector Switch (Basic Switch)....6373
Auto-deceleration Switch (Selection Switch)....6374
Travel Speed Selector Switch (Selection Switch)....6375
Wiper Switch....6376
Window Washer Switch....6377
Maintenance Switch....6377
User Mode Adjustment Switch....6379
Fan Reverse Rotation....6379
Adjusting Set Value of Economy Mode....6382
Back Switch....6383
Up Switch, Down Switch....6383
Input Confirmation Switch....6384
Liquid Crystal Monitor Adjustment Switch....6384
Adjusting Brightness....6384
Adjusting Contrast....6385
Alarm Buzzer Stop Switch....6386
SWITCHES....6387
Starting Switch....6387
Fuel Control Dial....6388
Cigarette Lighter....6388
Machine Push-up Switch....6388
Lamp Switch....6389
Swing Lock Switch....6389
Boom Shockless Control Switch....6390
Horn Switch....6390
Room Lamp Switch....6390
Emergency Pump Drive Switch....6391
Swing Brake Cancel Switch....6391
Revolving Warning Lamp Switch....6391
Lower Wiper Switch....6392
Step Light Switch....6392
One-Touch Power Max. Switch....6392
Large Capacity Airflow Air Conditioner Blower Switch....6393
CONTROL LEVERS AND PEDALS....6394
Lock Lever....6394
Travel Levers (with Pedals and Auto-deceleration Device)....6395
Work Equipment Control Lever....6395
SUN ROOF....6397
Opening....6397
Closing....6397
WINDSHIELD....6398
Opening....6398
Closing....6401
Removing Lower Windshield....6402
EMERGENCY EXIT FROM OPERATOR'S CAB....6403
DOOR LOCK....6403
CAP WITH LOCK....6404
Opening and Closing Caps with Lock....6404
Opening the Cap....6404
Locking the Cap....6404
Opening and Closing Cover with Lock....6404
Opening the Cover (Locked Cover)....6404
Locking the Cover....6404
HOT AND COOL BOX....6405
MAGAZINE BOX....6405
ASHTRAY....6405
AIR CONDITIONER CONTROLS....6406
Air Conditioner Control Panel....6406
OFF Switch....6406
Fan Switch....6406
Temperature Control Switch....6407
Vent Selector Switch....6407
Auto Switch....6408
FRESH/RECIRC Selector Switch....6409
Display Monitor....6409
Air Conditioner Switch....6409
Sunlight Sensor....6410
Method of Operation....6410
Automatic Operation....6410
Stopping Automatic Operation....6411
Manual Operation....6411
Stopping Manual Operation....6413
Operation with Cold Air to Face and Warm Air to Feet....6413
Defroster Operation....6414
Use Air Conditioner with Care....6416
Ventilation....6416
Temperature Control....6416
Inspection and maintenance of Air Conditioner Equipped Machine....6416
Other Functions....6417
Self-diagnostic Function....6417
Function to Switch Set Temperature Display Between Fahrenheit and Celsius....6418
CAB RADIO....6418
Antenna....6418
Use Radio With Care....6418
AUXILIARY ELECTRIC POWER....6419
24V power source....6419
12V power source....6419
FUSE....6420
Fuse Capacities and Circuit Names....6420
CIRCUIT BREAKER....6421
CONTROLLER....6422
TOOL BOX....6422
GREASE PUMP....6423
Method of Use....6423
Precautions when Using....6424
Supplying Grease....6424
ACCUMULATOR....6426
Releasing Hydraulic Pressure With Accumulator....6426
MACHINE OPERATIONS AND CONTROLS....6427
BEFORE STARTING ENGINE....6427
Walk-around Checks....6427
Checks Before Starting....6428
Check Coolant Level, Add Coolant....6428
Check Oil Level in Engine Oil Pan, Add Oil....6429
Check Fuel Level, Add Fuel....6430
Check for Water and Sediment in Water Separator, Drain Water....6431
Drain Water And Sediment from Fuel Tank....6432
Check Oil Level in Hydraulic Tank, Add Oil....6432
Check Oil Level in Swing Machinery Case, Add Oil....6433
Check Oil Level in P.T.O Case, Add Oil....6434
Check Working Lamp Switch....6435
Check Electric Wiring....6436
Check Function of Horn....6436
Adjustment....6437
Seat Adjustment....6437
Rearview Mirrors....6439
Seat Belt....6440
Fastening and Removing....6440
Fastening Seat Belt....6440
Removing Belt....6440
Operations Before Starting Engine....6441
STARTING ENGINE....6444
AFTER STARTING ENGINE....6447
Warming Up Engine....6447
Warming Up Hydraulic Equipment....6449
Operation After Completion Of Warming-Up Operation....6453
STOPPING THE ENGINE....6454
MACHINE OPERATION....6455
Preparations for Moving the Machine....6455
Moving Machine Forward....6456
Moving Machine Backward....6457
Stopping Machine....6458
STEERING THE MACHINE....6459
Steering....6459
Steering the Machine when Stopped....6459
Changing Direction of the Machine....6460
Counter-rotation Turn (Spin Turn)....6460
SWINGING....6461
WORK EQUIPMENT CONTROLS AND OPERATIONS....6462
WORKING MODE....6463
Working Mode....6463
Setting Economy Mode....6464
PROHIBITED OPERATIONS....6465
Operations Using Swing Force....6465
Operations Using Travel Force....6465
Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends....6465
Operations Using Bucket Dropping Force....6466
Operations Using Machine Dropping Force....6466
Digging Hard Rocky Ground....6466
Sudden Lever Shifting High Speed Travel....6466
GENERAL OPERATION INFORMATION....6467
Traveling....6467
High Speed Travel....6467
Precautions when Carrying Out Operations Continually with the Work Equipment in the Same Posture....6467
Permissible Water Depth....6468
TRAVELING ON SLOPES....6469
Traveling Downhill....6470
Engine Stopped on Slope....6470
Cab Doors on Slope....6470
ESCAPE FROM MUD....6471
Track on One Side Stuck....6471
Tracks on Both Sides Stuck....6471
RECOMMENDED APPLICATIONS....6472
Backhoe Work....6472
Ditching Work....6472
Loading Work....6472
BUCKET REPLACEMENT....6473
Replacement....6473
PARKING MACHINE....6475
MACHINE INSPECTION AFTER DAILY WORK....6476
LOCKING....6477
OVERLOAD WARNING DEVICE (option)....6477
TRANSPORTATION....6478
PRECAUTIONS FOR TRANSPORTATION....6478
LIFTING MACHINE....6478
SHIPPING MACHINE INFORMATION....6480
TRANSPORTATION POSTURE....6481
Three units for transportation....6481
Posture for Each Unit....6482
Upper Structure + Undercarriage....6482
Upper Structure....6482
Undercarriage....6482
Work Equipment....6483
Others....6484
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....6486
Reducing Track Gauge....6486
Increasing Track Gauge....6487
COLD WEATHER OPERATION....6488
COLD WEATHER OPERATION INFORMATION....6488
Fuel and Lubricants....6488
Cooling System Coolant....6488
Battery....6489
Monitor....6490
AFTER DAILY WORK COMPLETION....6491
AFTER COLD WEATHER SEASON....6491
LONG TERM STORAGE....6492
BEFORE STORAGE....6492
DURING STORAGE....6492
AFTER STORAGE....6493
STARTING MACHINE AFTER LONG-TERM STORAGE....6493
TROUBLES AND ACTIONS....6494
RUNNING OUT OF FUEL....6494
Procedure for Bleeding Air....6494
PHENOMENA THAT ARE NOT FAILURES....6495
TOWING THE MACHINE....6496
SEVERE JOB CONDITION....6496
DISCHARGED BATTERY....6497
Battery Removal and Installation....6497
Battery Charges....6498
Starting Engine with Booster Cables....6499
Connecting and Disconnecting Booster Cables....6499
Booster Cable Connection....6500
Starting the Engine....6500
Booster Cable Disconnection....6500
OTHER TROUBLE....6501
Electrical System....6501
Chassis....6502
Engine....6503
Electronic Control System....6505
Machine Monitoring System....6505
Point of Contact to Telephone when Error Occurs....6506
MAINTENANCE INFORMATION....6509
Service Meter Reading....6509
Komatsu Genuine Replacement Parts....6509
Komatsu Genuine Lubricants....6509
Windshield Washer Fluid....6509
Fresh and Clean Lubricants....6509
Check Drained Oil and Used Filter....6509
Fuel Strainer....6509
Welding Instructions....6509
Do not Drop Things Inside Machine....6509
Dusty Jobsite....6510
Avoid Mixing Lubricants....6510
Locking the Inspection Covers....6510
Hydraulic System - Air Bleeding....6510
Hydraulic Hose Installation....6510
Checks After Inspection and Maintenance Works....6510
OUTLINE OF SERVICE....6511
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....6511
Oil....6511
Fuel....6511
Cooling System Coolant....6512
Grease....6512
Carrying Out KOWA (Komatsu Oil Wear Analysis)....6513
KOWA Analysis Items....6513
Oil Sampling....6513
Oil and Fuel Storage....6514
Filters....6514
ELECTRIC SYSTEM MAINTENANCE....6515
WEAR PARTS....6516
WEAR PARTS LIST....6516
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS....6517
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....6518
TIGHTENING TORQUE SPECIFICATIONS....6519
TIGHTENING TORQUE LIST....6519
SAFETY CRITICAL PARTS....6520
SAFETY CRITICAL PARTS LIST....6521
MAINTENANCE SCHEDULE....6522
MAINTENANCE SCHEDULE CHART....6522
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)....6522
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)....6522
WHEN REQUIRED....6522
CHECKS BEFORE STARTING....6522
EVERY 10 HOURS MAINTENANCE....6522
EVERY 100 HOURS MAINTENANCE....6522
EVERY 250 HOURS MAINTENANCE....6522
EVERY 500 HOURS MAINTENANCE....6523
EVERY 1000 HOURS MAINTENANCE....6523
EVERY 2000 HOURS MAINTENANCE....6523
EVERY 4000 HOURS MAINTENANCE....6523
EVERY 5000 HOURS MAINTENANCE....6523
EVERY 8000 HOURS MAINTENANCE....6523
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....6524
REPLACE HYDRAULIC OIL FILTER ELEMENT....6524
CHANGE OIL IN HYDRAULIC TANK....6524
REPLACE ADDITIONAL FILTER ELEMENT FOR BREAKER....6524
MAINTENANCE PROCEDURE....6525
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)....6525
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)....6525
WHEN REQUIRED....6526
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....6526
Checking....6526
Cleaning or Replacing Outer Element....6527
Install Air Cleaner Element....6529
CLEAN INSIDE OF COOLING SYSTEM....6531
CHECK AND TIGHTEN TRACK SHOE BOLTS....6534
Tightening....6534
Order for Tightening....6534
CHECK AND ADJUST TRACK TENSION....6535
Checking....6535
Adjustment....6535
Increasing Track Tension....6535
Loosening Track Tension....6536
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)....6537
ADJUST BUCKET CLEARANCE....6538
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID....6539
Mixture Ratio of Pure Washer Fluid and Water....6539
CHECK AND MAINTENANCE AIR CONDITIONER....6540
Check Level of Refrigerant (gas)....6540
Inspection During Off Season....6540
Inspection and Maintenance Items....6540
CLEAN LINE FILTER, REMOVE DIRT....6541
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT....6542
CLEAN PILOT LINE FILTER, REMOVE DIRT....6543
BLEEDING AIR FROM HYDRAULIC SYSTEM....6544
Operation....6546
CHECK BEFORE STARTING....6547
EVERY 10 HOURS MAINTENANCE....6548
LUBRICATING....6548
EVERY 100 HOURS MAINTENANCE....6551
LUBRICATING SWING CIRCLE....6551
EVERY 250 HOURS MAINTENANCE....6552
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....6552
CHECK LEVEL OF BATTERY ELECTROLYTE....6553
When Checking Electrolyte Level from Side of Battery....6554
When it is Impossible to Check Electrolyte Level from Side of Battery....6554
When it is Possible to Use Indicator to Check Electrolyte Level....6554
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS....6555
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST....6556
Checking....6556
Adjustment....6556
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....6557
Checking....6557
Adjustment....6557
EVERY 500 HOURS MAINTENANCE....6558
REPLACE FUEL PRE-FILTER CARTRIDGE....6558
CHECK SWING PINION GREASE LEVEL, ADD GREASE....6561
CLEAN,CHECK RADIATOR FINS,OIL COOLER FINS,FUEL COOLER FINS,AFTERCOOLER FINS,CONDENSER FINS (machines equipped with air conditioner),PTO OIL COOLER FINS....6562
CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)....6564
CLEAN RECIRC AIR FILTER....6564
CLEAN FRESH AIR FILTER....6564
CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER....6565
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....6566
EVERY 1000 HOURS MAINTENANCE....6568
REPLACE FUEL MAIN FILTER CARTRIDGE....6568
REPLACE HYDRAULIC OIL FILTER ELEMENT....6571
CHANGE OIL IN SWING MACHINERY CASE....6572
CHANGE OIL IN P.T.O CASE....6573
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS....6574
REPLACE CORROSION RESISTOR CARTRIDGE....6574
CHECK WELDED STRUCTURE....6575
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT....6578
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)....6578
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK....6579
EVERY 2000 HOURS MAINTENANCE....6580
CHANGE OIL IN FINAL DRIVE CASE....6580
CLEAN HYDRAULIC TANK STRAINER....6581
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)....6582
FUNCTION OF ACCUMULATOR....6582
CHECKING FUNCTION OF ACCUMULATOR....6583
METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT....6585
CHECK ALTERNATOR, STARTING MOTOR....6585
EVERY 4000 HOURS MAINTENANCE....6586
CHECK WATER PUMP....6586
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)....6586
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER....6586
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER....6588
CHECK OPERATING CONDITION OF COMPRESSOR....6588
EVERY 5000 HOURS MAINTENANCE....6589
CHANGE OIL IN HYDRAULIC TANK....6589
EVERY 8000 HOURS MAINTENANCE....6590
REPLACE HIGH-PRESSURE PIPING CLAMP....6590
REPLACE FUEL SPRAY PREVENTION CAP....6590
SPECIFICATIONS....6593
GENERAL PRECAUTIONS FOR SAFETY....6597
PRECAUTIONS WHEN SELECTING....6597
READ THE INSTRUCTION MANUAL THOROUGHLY....6597
PRECAUTIONS WHEN REMOVING OR INSTALLING....6597
PRECAUTIONS WHEN USING....6598
ATTACHMENT GUIDE....6599
COMBINATIONS OF WORK EQUIPMENT....6599
Working Range Diagram....6600
TRACK SHOES SELECTION....6601
Selection....6601
HANDLING MACHINES EQUIPPED WITH KOMTRAX....6602
BASIC PRECAUTIONS....6602
