Komatsu Hydraulic Excavator PC600 8PC600 LC-8 PC800 K50001 PC 800 LC-K Service Repair Manual Download
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Komatsu Hydraulic Excavator PC600 8PC600 LC-8 PC800 K50001 PC 800 LC-K Service Repair Manual Download
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- Komatsu Hydraulic Excavator PC600 8PC600 LC-8 PC800 K50001 PC 800 LC-K Service Repair Manual Download
- 1. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information.
- 01. Specification This section explains the specifications of the machine.
- 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
- 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
- 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
- 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
- 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
- 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu Hydraulic Excavator PC600 8PC600 LC-8 PC800 K50001 PC 800 LC-K Service Repair Manual Download
00 Index and foreword.................................................................... 3
Organization list of the shop manual................................................. 4
Table of contents.................................................................... 6
00 Index and foreword.................................................................... 15
Foreword and general information..................................................... 16
Safety notice.................................................................... 16
How to read the shop manual...................................................... 20
Explanation of terms for maintenance standard.................................... 22
Handling electric equipment and hydraulic component.............................. 24
How to read electric wire code................................................... 32
Method of disassembling and connecting push-pull type coupler.................... 35
Standard tightening torque table................................................. 38
Conversion table................................................................. 42
01 Specification......................................................................... 49
Specification and technical data..................................................... 50
Specification drawings........................................................... 50
Working range drawings........................................................... 51
Specifications................................................................... 52
Weight table..................................................................... 58
Table of fuel, coolant and lubricants............................................ 60
10 Structure, function and maintenance standard.......................................... 63
Engine and cooling system............................................................ 64
Parts related to engine.......................................................... 64
PTO.............................................................................. 66
Fan, control and PTO lubrication pump............................................ 68
Radiator, oil cooler............................................................. 69
10 Structure, function and maintenance standard.......................................... 71
Power train.......................................................................... 72
Power train...................................................................... 72
Final drive...................................................................... 75
Sprocket......................................................................... 78
Swing circle..................................................................... 80
Swing machinery.................................................................. 82
10 Structure, function and maintenance standard.......................................... 85
Undercarriage and frame.............................................................. 86
Track frame, recoil spring....................................................... 86
Idler............................................................................ 88
Carrier roller................................................................... 90
Track roller..................................................................... 91
Track shoe....................................................................... 92
10 Structure, function and maintenance standard.......................................... 99
Hydraulic system, Part 1.............................................................100
Hydraulic piping drawing.........................................................100
Hydraulic tank, hydraulic filter.................................................102
Hydraulic pump (piston pump).....................................................104
Line oil filter..................................................................132
Cooling fan pump.................................................................134
Cooling fan motor................................................................142
10 Structure, function and maintenance standard..........................................149
Hydraulic system, Part 2.............................................................150
Control valve....................................................................150
Swing motor......................................................................169
Swing brake......................................................................172
Safety valve.....................................................................173
Reverse prevention valve.........................................................175
Center swivel joint..............................................................178
Travel motor.....................................................................179
Parking brake....................................................................184
Brake valve......................................................................186
Set pressures varying mechanism..................................................189
Valve control....................................................................190
Work equipment, swing PPC valve..................................................192
Travel PPC valve.................................................................196
Service PPC valve................................................................198
PPC accumulator..................................................................199
PPC shuttle valve................................................................200
Solenoid valve...................................................................201
Boom holding valve...............................................................206
Boom LOWER regeneration valve....................................................210
Hydraulic drift prevention valve.................................................214
Hydraulic cylinder...............................................................220
10 Structure, function and maintenance standard..........................................223
Work equipment.......................................................................224
Work equipment...................................................................224
Dimensions of work equpment......................................................226
10 Structure, function and maintenance standard..........................................231
Cab and its attachments..............................................................232
Air conditioner piping...........................................................232
10 Structure, function and maintenance standard..........................................235
Engine control.......................................................................236
Machine control system diagram.......................................................241
Monitor system.......................................................................265
Sensors..............................................................................280
20 Standard value table..................................................................285
Standard service value table.........................................................286
Standard value table for engine..................................................286
Standard value table for chassis.................................................287
30 Testing and adjusting.................................................................297
Testing and adjusting, Part 1........................................................300
Tools for testing, adjusting and troubleshooting.................................300
Measuring engine speed...........................................................302
Measuring intake air pressure (boost pressure)...................................303
Measuring exhaust gas temperature................................................304
Measuring exhaust gas color......................................................305
Adjusting valve clearance........................................................306
Measuring compression pressure...................................................307
Measuring blow-by pressure.......................................................309
Measuring engine oil pressure....................................................309
Handling equipment in fuel circuit...............................................310
Releasing remaining pressure in fuel system......................................310
Measuring fuel pressure..........................................................311
Reduced cylinder mode operation..................................................312
No-injection cranking............................................................312
Testing leakage from pressure limiter and return rate from injector..............313
Bleeding air from fuel circuit...................................................315
Testing fuel system for leakage..................................................316
Adjusting speed sensor...........................................................317
Testing and adjusting alternator belt tension....................................317
Testing and adjusting air conditioner compressor belt tension....................318
Testing clearance of swing circle bearing........................................319
Testing and adjusting track shoe tension.........................................320
Testing and adjusting work equipment, swing, and travel circuit oil pressures....321
Testing and adjusting control circuit oil pressure...............................326
Testing and adjusting piston pump control oil pressure...........................328
Testing servo piston stroke......................................................334
Measuring PPC valve output pressure..............................................335
Measuring outlet pressures of solenoid valve and PPC shuttle valve...............340
Adjusting work equipment, swing PPC valve........................................346
Testing and adjusting travel deviation...........................................347
Measuring fan speed..............................................................349
Measuring fan circuit oil pressure...............................................349
Inspection of locations of hydraulic drift of work equipment.....................350
Measuring oil leakage............................................................351
Releasing remaining pressure in hydraulic circuit................................355
Bleeding air from each part......................................................356
Inspection procedures for diode..................................................359
30 Testing and adjusting.................................................................361
Testing and adjusting, Part 2........................................................362
Special function of machine monitor..............................................362
Handling engine controller high voltage circuit..................................394
Preparation work for troubleshooting electrical system...........................395
Pm-CLINIC SERVICE................................................................397
Pm-CLINIC SERVICE PC600, 600LC-8.................................................402
UNDERCARRIAGE INSPECTION.........................................................403
40 Troubleshooting.......................................................................405
General information on troubleshooting...............................................406
Points to remember when troubleshooting..........................................406
Sequence of events in troubleshooting............................................407
Checks before troubleshooting....................................................408
Classification and procedures of troubleshooting.................................409
Connection table for connector pin numbers.......................................413
T-boxes and T-adapters table.....................................................436
40 Troubleshooting.......................................................................441
Troubleshooting by failure code (Display of code), Part 1............................444
40 Troubleshooting.......................................................................505
Troubleshooting by failure code (Display of code), Part 2............................508
40 Troubleshooting.......................................................................571
Troubleshooting by failure code (Display of code), Part 3............................574
40 Troubleshooting.......................................................................643
Troubleshooting of electrical system (E-mode)........................................646
40 Troubleshooting.......................................................................703
Troubleshooting of hydraulic and mechanical system (H-mode)..........................705
40 Troubleshooting.......................................................................745
Troubleshooting of engine (S-mode)...................................................747
50 Disassembly and assembly..............................................................773
General information on disassembly and assembly......................................774
How to read this manual..........................................................774
Coating materials list...........................................................776
Special tools list...............................................................779
Sketches of special tools........................................................785
50 Disassembly and assembly..............................................................791
Engine and cooling system, Part 1....................................................792
Removal and installation of engine, PTO and hydraulic pump assembly..............792
Removal and installation of radiator assembly....................................799
Removal and installation of hydraulic oil cooler assembly........................801
Removal and installation of aftercooler assembly.................................803
Removal and installation of fan motor assembly...................................805
Removal and installation of fuel tank assembly...................................809
50 Disassembly and assembly..............................................................811
Engine and cooling system, Part 2....................................................812
Removal and installation of fuel supply pump assembly............................812
Removal and installation of cylinder head assembly...............................817
Removal and installation of fuel injector assembly...............................833
Removal and installation of engine front seal....................................836
Removal and installation of engine rear seal.....................................838
50 Disassembly and assembly..............................................................843
Power train..........................................................................844
Removal and installation of PTO assembly.........................................844
Disassembly and assembly of PTO assembly.........................................846
Removal and installation of swing motor and swing machinery assembly.............849
Disassembly and assembly of swing machinery assembly.............................850
Removal and installation of swing circle assembly................................857
Disassembly and assembly of final drive assembly.................................858
50 Disassembly and assembly..............................................................869
Undercarriage and frame..............................................................870
Removal and installation of revolving frame assembly.............................870
Disassembly and assembly of 1 link in field......................................872
Removal and installation of idler, recoil spring assembly........................876
Disassembly and assembly of idler assembly.......................................877
Disassembly and assembly of recoil spring assembly...............................880
Removal and installation of track roller assembly................................882
Disassembly and assembly of track roller assembly................................883
Removal and installation of carrier roller assembly..............................886
Disassembly and assembly of carrier roller assembly..............................887
Removal and installation of revolving frame assembly.............................890
Removal and installation of counterweight assembly...............................892
Removal and installation of counterweight remover assembly.......................893
50 Disassembly and assembly..............................................................897
Hydraulic system.....................................................................898
Removal and installation of hydraulic tank assembly..............................898
Removal and installation of hydraulic pump assembly..............................900
Removal and installation of control valve and solenoid valve assembly............903
Disassembly and assembly of control valve assembly...............................905
Disassembly and assembly of main control valve assembly..........................906
Removal and installation of swing motor assembly.................................910
Removal and installation of center swivel joint assembly.........................911
Disassembly and assembly of center swivel joint assembly.........................912
Disassembly and assembly of work equipment PPC valve assembly....................913
Disassembly and assembly of travel PPC valve assembly............................915
Disassembly and assembly of hydraulic cylinder assembly..........................917
50 Disassembly and assembly..............................................................923
Work equipment.......................................................................924
Removal and installation of bucket cylinder assembly.............................924
Removal and installation of arm cylinder assembly................................926
Removal and installation of boom cylinder assembly...............................928
Removal and installation of bucket assembly......................................930
Removal and installation of arm assembly.........................................932
Removal and installation of boom assembly........................................934
50 Disassembly and assembly..............................................................937
Cab and its attachments..............................................................938
Removal and installation of operator’s cab.......................................938
Removal and installation of operator’s cab glass (stuck glass)...................941
Removal and installation of front window assembly................................951
50 Disassembly and assembly..............................................................957
Electrical system....................................................................958
Removal and installation of air conditioner unit assembly........................958
Removal and installation of engine controller assembly...........................960
Removal and Installation of KOMTRAX terminal assembly............................962
Removal and installation of pump controller......................................962
Removal and installation of monitor assembly.....................................963
90 Diagrams and drawings.................................................................965
Hydraulic circuit diagram............................................................967
90 Diagrams and drawings.................................................................971
Electrical circuit diagram (1/5).....................................................973
Electrical circuit diagram (2/5).....................................................975
Electrical circuit diagram (3/5).....................................................977
Electrical circuit diagram (4/5).....................................................979
Electrical circuit diagram (5/5).....................................................981
Electrical circuit diagram for air conditioner.......................................983
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