KOMATSU PC650-3 PC650LC-3 PC650SE-3 SHOP MANUAL SEBM02090307 – PDF DOWNLOAD

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KOMATSU PC650-3 PC650LC-3 PC650SE-3 SHOP MANUAL SEBM02090307 – PDF DOWNLOAD

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KOMATSU PC650-3 PC650LC-3 PC650SE-3 SHOP MANUAL SEBM02090307 – PDF DOWNLOAD

Language : English
Pages : 801
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

KOMATSU PC650-3 PC650LC-3 PC650SE-3 SHOP MANUAL SEBM02090307 – PDF DOWNLOAD

COVER..................................................................................................................................................................................................  1
CONTENTS...............................................................................................................................................................................................  2
10 ENGINE.............................................................................................................................................................................................. 27
	11 STRUCTURE AND FUNCTION.......................................................................................................................................................................... 27
		ENGINE RELATED PARTS........................................................................................................................................................................... 28
		PTO (POWER TAKE-OFF)........................................................................................................................................................................... 29
		PTO LUBRICATION SYSTEM......................................................................................................................................................................... 30
		RADIATOR AND OIL COOLER........................................................................................................................................................................ 31
		FUEL TANK AND PIPING........................................................................................................................................................................... 32
		ENGINE CONTROL SYSTEM.......................................................................................................................................................................... 33
		AUTO-DECELERATION SYSTEM (IF EQUIPPED)......................................................................................................................................................... 34
	12 TESTING AND ADJUSTING........................................................................................................................................................................... 42
		STANDARD FOR TESTING AND ADJUSTING............................................................................................................................................................. 43
		TESTING AND ADJUSTING TOOL LIST................................................................................................................................................................ 43
		ADJUSTING VALVE CLEARANCE...................................................................................................................................................................... 44
		MEASURING COMPRESSION PRESSURE................................................................................................................................................................. 45
		ADJUSTING FUEL INJECTION TIMING................................................................................................................................................................ 46
		MEASURING EXHAUST GAS COLOR.................................................................................................................................................................... 47
		MEASURING BLOW-BY PRESSURE..................................................................................................................................................................... 48
		TESTING AND ADJUSTING FAN BELT TENSION......................................................................................................................................................... 49
		TESTING AND ADJUSTING ALTERNATOR BELT TENSION.................................................................................................................................................. 49
		ADJUSTING FUEL CONTROL LEVER................................................................................................................................................................... 50
		ADJUSTING AUTO-DECELERATION SYSTEM............................................................................................................................................................. 53
	13 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................................ 54
		STARTING MOTOR................................................................................................................................................................................. 55
			REMOVAL.................................................................................................................................................................................... 55
			INSTALLATION............................................................................................................................................................................... 55
		ALTERNATOR..................................................................................................................................................................................... 55
			REMOVAL.................................................................................................................................................................................... 55
			INSTALLATION............................................................................................................................................................................... 55
		ENGINE OIL COOLER.............................................................................................................................................................................. 55
			REMOVAL.................................................................................................................................................................................... 55
			INSTALLATION............................................................................................................................................................................... 55
		FUEL INJECTION PUMP............................................................................................................................................................................ 57
			REMOVAL.................................................................................................................................................................................... 57
			INSTALLATION............................................................................................................................................................................... 57
		WATER PUMP..................................................................................................................................................................................... 57
			REMOVAL.................................................................................................................................................................................... 57
			INSTALLATION............................................................................................................................................................................... 57
		NOZZLE HOLDER.................................................................................................................................................................................. 59
			REMOVAL.................................................................................................................................................................................... 59
			INSTALLATION............................................................................................................................................................................... 59
		TURBOCHARGER................................................................................................................................................................................... 59
			REMOVAL.................................................................................................................................................................................... 59
			INSTALLATION............................................................................................................................................................................... 59
		CYLINDER HEAD.................................................................................................................................................................................. 61
			REMOVAL.................................................................................................................................................................................... 61
			INSTALLATION............................................................................................................................................................................... 65
		HYDRAULIC OIL COOLER........................................................................................................................................................................... 69
			REMOVAL.................................................................................................................................................................................... 69
			INSTALLATION............................................................................................................................................................................... 69
		RADIATOR....................................................................................................................................................................................... 69
			REMOVAL.................................................................................................................................................................................... 69
			INSTALLATION............................................................................................................................................................................... 69
		ENGINE, PTO AND HYDRAULIC PUMP................................................................................................................................................................. 71
			REMOVAL.................................................................................................................................................................................... 71
			INSTALLATION............................................................................................................................................................................... 75
		PTO............................................................................................................................................................................................ 79
			REMOVAL.................................................................................................................................................................................... 79
			INSTALLATION............................................................................................................................................................................... 79
			DISASSEMBLY................................................................................................................................................................................ 81
			ASSEMBLY................................................................................................................................................................................... 81
		DECELERATOR CYLINDER (IF EQUIPPED)............................................................................................................................................................. 85
			REMOVAL.................................................................................................................................................................................... 85
			INSTALLATION............................................................................................................................................................................... 85
	14 MAINTENANCE STANDARD............................................................................................................................................................................ 87
		PTO............................................................................................................................................................................................ 88
20 POWER TRAIN......................................................................................................................................................................................... 89
	21 STRUCTURE AND FUNCTION.......................................................................................................................................................................... 89
		POWER TRAIN ................................................................................................................................................................................... 90
		TRAVEL AND BRAKE SYSTEM........................................................................................................................................................................ 92
			1. OUTLINE................................................................................................................................................................................. 92
			2. TRAVEL CONTROL CIRCUIT SCHEMATICS....................................................................................................................................................... 94
			3. TRAVEL CONTROL CIRCUIT.................................................................................................................................................................. 96
			4. STRAIGHT-TRAVEL SYSTEM.................................................................................................................................................................. 98
			5. CENTER SWIVEL JOINT.....................................................................................................................................................................104
			6. TRAVEL MOTOR (WITH PARKING BRAKE) ASSEMBLY..............................................................................................................................................105
			7. TRAVEL BRAKE VALVE......................................................................................................................................................................121
			8. FINAL DRIVE.............................................................................................................................................................................124
		SWING SYSTEM...................................................................................................................................................................................127
			1. OUTLINE.................................................................................................................................................................................127
			2. SWING HYDRAULIC CIRCUIT SCHEMATICS......................................................................................................................................................128
			3. SWING HYDRAULIC CIRCUIT.................................................................................................................................................................129
			4. SWING PUMP..............................................................................................................................................................................130
			5. SWING CONTROL VALVE.....................................................................................................................................................................133
			6. SWING MOTOR (WITH MECHANICAL BRAKE) AND SAFETY VALVE ASSEMBLY...........................................................................................................................137
			7. SWING BRAKE (AUTOMATIC) AND SWING PARKING BRAKE (MANUAL)................................................................................................................................143
			8. FREE SWING SYSTEM.......................................................................................................................................................................147
			9. SWING MACHINERY.........................................................................................................................................................................152
			10. SWING CIRCLE...........................................................................................................................................................................154
	23 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................................155
		CENTER SWIVEL JOINT............................................................................................................................................................................156
			REMOVAL....................................................................................................................................................................................156
			INSTALLATION...............................................................................................................................................................................156
			DISASSEMBLY................................................................................................................................................................................158
			ASSEMBLY...................................................................................................................................................................................158
		TRAVEL MOTOR (WITH FOUR TRAVEL MOTORS).........................................................................................................................................................160
			REMOVAL....................................................................................................................................................................................160
			INSTALLATION...............................................................................................................................................................................160
			DISASSEMBLY................................................................................................................................................................................164
			ASSEMBLY...................................................................................................................................................................................170
		TRAVEL BRAKE VALVE (WITH FOUR TRAVEL MOTORS)...................................................................................................................................................160
			REMOVAL....................................................................................................................................................................................160
			INSTALLATION...............................................................................................................................................................................160
		TRAVEL MOTOR (WITH TWO TRAVEL MOTORS)..........................................................................................................................................................162
			REMOVAL....................................................................................................................................................................................162
			INSTALLATION...............................................................................................................................................................................162
			DISASSEMBLY................................................................................................................................................................................180
			ASSEMBLY...................................................................................................................................................................................193
		FINAL DRIVE....................................................................................................................................................................................209
			REMOVAL (WITH FOUR TRAVEL MOTORS)..........................................................................................................................................................209
			INSTALLATION (WITH FOUR TRAVEL MOTORS).....................................................................................................................................................209
			REMOVAL (WITH TWO TRAVEL MOTORS)...........................................................................................................................................................211
			INSTALLATION (WITH TWO TRAVEL MOTORS)......................................................................................................................................................211
			DISASSEMBLY (WITH FOUR TRAVEL MOTORS)......................................................................................................................................................213
			ASSEMBLY (WITH FOUR TRAVEL MOTORS).........................................................................................................................................................217
			DISASSEMBLY (WITH TWO TRAVEL MOTORS).......................................................................................................................................................225
			ASSEMBLY (WITH TWO TRAVEL MOTORS)..........................................................................................................................................................229
		SPROCKET.......................................................................................................................................................................................237
			REMOVAL....................................................................................................................................................................................237
			INSTALLATION...............................................................................................................................................................................237
		SWING PUMP.....................................................................................................................................................................................239
			REMOVAL....................................................................................................................................................................................239
			INSTALLATION...............................................................................................................................................................................239
			DISASSEMBLY................................................................................................................................................................................241
			ASSEMBLY...................................................................................................................................................................................245
		CO・NC VALVE (FOR SWING PUMP)...................................................................................................................................................................255
			REMOVAL....................................................................................................................................................................................255
			INSTALLATION...............................................................................................................................................................................255
		SERVO VALVE (FOR SWING PUMP)...................................................................................................................................................................255
			REMOVAL....................................................................................................................................................................................255
			INSTALLATION...............................................................................................................................................................................255
		SWING CONTROL VALVE............................................................................................................................................................................255
			REMOVAL....................................................................................................................................................................................255
			INSTALLATION...............................................................................................................................................................................255
			DISASSEMBLY................................................................................................................................................................................257
			ASSEMBLY...................................................................................................................................................................................257
		MAIN RELIEF VALVE (FOR SWING CONTROL VALVE)....................................................................................................................................................257
			REMOVAL....................................................................................................................................................................................257
			INSTALLATION...............................................................................................................................................................................257
		SWING MOTOR....................................................................................................................................................................................259
			REMOVAL....................................................................................................................................................................................259
			INSTALLATION...............................................................................................................................................................................259
			DISASSEMBLY................................................................................................................................................................................261
			ASSEMBLY...................................................................................................................................................................................265
		REVOLVING FRAME................................................................................................................................................................................269
			REMOVAL....................................................................................................................................................................................269
			INSTALLATION...............................................................................................................................................................................269
		SWING CIRCLE...................................................................................................................................................................................271
			REMOVAL....................................................................................................................................................................................271
			INSTALLATION...............................................................................................................................................................................271
		SWING MACHINERY................................................................................................................................................................................273
			REMOVAL....................................................................................................................................................................................273
			INSTALLATION...............................................................................................................................................................................273
			DISASSEMBLY................................................................................................................................................................................275
			ASSEMBLY...................................................................................................................................................................................279
	24 MAINTENANCE STANDARD............................................................................................................................................................................283
		TRAVEL MOTOR...................................................................................................................................................................................284
		TRAVEL SHUTTLE VALVE...........................................................................................................................................................................285
		STRAIGHT-TRAVEL VALVE..........................................................................................................................................................................286
		TRAVEL BRAKE VALVE.............................................................................................................................................................................287
		FINAL DRIVE....................................................................................................................................................................................289
		SWING CONTROL VALVE............................................................................................................................................................................293
		JET SENSOR.....................................................................................................................................................................................295
		SWING MOTOR....................................................................................................................................................................................296
		SWING SHADOW VALVE (IF EQUIPPED)...............................................................................................................................................................297
		CONNECTION VALVE (IF EQUIPPED).................................................................................................................................................................298
		SWING MACHINERY................................................................................................................................................................................299
		SWING CIRCLE...................................................................................................................................................................................301
30 UNDERCARRIAGE.......................................................................................................................................................................................302
	31 STRUCTURE AND FUNCTION..........................................................................................................................................................................302
		TRACK FRAME....................................................................................................................................................................................303
		IDLER CUSHION..................................................................................................................................................................................305
		IDLER..........................................................................................................................................................................................309
		TRACK ROLLER...................................................................................................................................................................................310
		CARRIER ROLLER.................................................................................................................................................................................311
		TRACK SHOE.....................................................................................................................................................................................312
	33 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................................314
		IDLER..........................................................................................................................................................................................315
			REMOVAL....................................................................................................................................................................................315
			INSTALLATION...............................................................................................................................................................................315
		IDLER CUSHION..................................................................................................................................................................................315
			REMOVAL....................................................................................................................................................................................315
			INSTALLATION...............................................................................................................................................................................315
			DISASSEMBLY................................................................................................................................................................................317
			ASSEMBLY...................................................................................................................................................................................317
		IDLER ADJUSTMENT CYLINDER......................................................................................................................................................................317
			DISASSEMBLY................................................................................................................................................................................317
			ASSEMBLY...................................................................................................................................................................................317
		TRACK ROLLER...................................................................................................................................................................................319
			REMOVAL....................................................................................................................................................................................319
			INSTALLATION...............................................................................................................................................................................319
		CARRIER ROLLER.................................................................................................................................................................................319
			REMOVAL....................................................................................................................................................................................319
			INSTALLATION...............................................................................................................................................................................319
		TRACK SHOE.....................................................................................................................................................................................321
			REMOVAL....................................................................................................................................................................................321
			INSTALLATION...............................................................................................................................................................................321
	34 MAINTENANCE STANDARD............................................................................................................................................................................323
		TRACK FRAME....................................................................................................................................................................................324
		TRACK SHOE.....................................................................................................................................................................................325
		IDLER..........................................................................................................................................................................................327
		TRACK ROLLER...................................................................................................................................................................................329
		CARRIER ROLLER.................................................................................................................................................................................331
50 AIR SYSTEM..........................................................................................................................................................................................332
	51 STRUCTURE AND FUNCTION..........................................................................................................................................................................332
		AIR PIPING.....................................................................................................................................................................................333
		AIR CIRCUIT DIAGRAM............................................................................................................................................................................334
		AIR GOVERNOR...................................................................................................................................................................................335
		AIR TANK.......................................................................................................................................................................................335
		SAFETY VALVE...................................................................................................................................................................................336
		HORN VALVE.....................................................................................................................................................................................336
		GREASE PUMP....................................................................................................................................................................................337
60 HYDRAULIC SYSTEM....................................................................................................................................................................................338
	61 STRUCTURE AND FUNCTION..........................................................................................................................................................................338
		HYDRAULIC PIPING...............................................................................................................................................................................339
		HYDRAULIC CIRCUIT DIAGRAM......................................................................................................................................................................343
		WORK EQUIPMENT CONTROL.........................................................................................................................................................................347
		ELECTRONIC AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)...............................................................................................................................363
		HYDRAULIC TANK.................................................................................................................................................................................372
		MAIN PUMP......................................................................................................................................................................................373
		HYDRAULIC OIL FILTER...........................................................................................................................................................................392
		CHARGING AND PTO LUBRICATING PUMP..............................................................................................................................................................396
		2-STAGE AND 3-STAGE MODE SELECTOR OLSS (OPEN CENTER LOAD SENSING SYSTEM).......................................................................................................................397
		HYDRAULIC CONTROL VALVE........................................................................................................................................................................415
		PPC VALVE......................................................................................................................................................................................422
		PPC SHUTTLE VALVE..............................................................................................................................................................................428
		ACCUMULATOR....................................................................................................................................................................................430
		PILOT RELIEF VALVE.............................................................................................................................................................................431
		SAFETY LOCK VALVE..............................................................................................................................................................................433
		HYDRAULIC CYLINDER.............................................................................................................................................................................435
		WORK EQUIPMENT.................................................................................................................................................................................442
	62 TESTING AND ADJUSTING...........................................................................................................................................................................444
		TABLE OF JUDGEMENT STANDARD VALUE..............................................................................................................................................................445
		TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE...................................................................................................................................................454
		TESTING AND ADJUSTING TOOL LIST................................................................................................................................................................468
		TESTING TRAVEL AND OPERATING FORCE.............................................................................................................................................................469
		TESTING AND ADJUSTING MAIN RELIEF VALVE........................................................................................................................................................470
		TESTING CONTROL CIRCUIT PRESSURE...............................................................................................................................................................472
		MEASURING DISCHARGE OF MAIN PISTON PUMP........................................................................................................................................................475
		CHECKING AND ADJUSTING TRAVEL MOTOR PERFORMANCE................................................................................................................................................476
		MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR..............................................................................................................................................479
		TESTING OIL LEAKAGE FROM SWIVEL JOINT..........................................................................................................................................................480
		BLEEDING AIR...................................................................................................................................................................................482
		CHARGING ACCUMULATOR WITH GAS..................................................................................................................................................................485
		TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK...............................................................................................................................................487
		ADJUSTMENT OF WORK EQUIPMENT POTENTIOMETER.....................................................................................................................................................488
		ADJUSTMENT OF WORK EQUIPMENT CONTROL BOX.......................................................................................................................................................489
		TROUBLESHOOTING................................................................................................................................................................................494
			ELECTRICAL CIRCUIT DIAGRAM.................................................................................................................................................................495
			POSITION OF CONNECTORS FOR TROUBLESHOOTING ................................................................................................................................................499
			CONNECTION TABLE FOR CONNECTOR PINS........................................................................................................................................................509
			TROUBLESHOOTING PROCEDURE..................................................................................................................................................................513
			CHECKS BEFORE TROUBLESHOOTING..............................................................................................................................................................514
			E.H MODE TROUBLESHOOTING...................................................................................................................................................................517
				ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY..............................................................................................................................518
				TROUBLESHOOTING (EXCEPT TROUBLESHOOTING FOR MACHINE MONITOR)...........................................................................................................................519
				E-1 MACHINE DEVIATES EXCESSIVELY.......................................................................................................................................................523
					a) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................524
					b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)...................................................................................526
				E-2 WORK EQUIPMENT, SWING, TRAVEL SPEEDS EXTREMELY SLOW, OR LACK OF POWER..............................................................................................................527
					a) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................527
					b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)...................................................................................529
				E-3 ENGINE STALLS DURING OPERATIONS, OR ENGINE SPEED DROPS.............................................................................................................................532
					a) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................532
					b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)...................................................................................534
				E-4 NO CHANGE IN OUTPUT WHEN MODE SWITCH IS OPERATED...................................................................................................................................535
					a) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................536
					b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)...................................................................................536
				E-5 AUTO-DECELERATION DOES NOT WORK....................................................................................................................................................541
					a) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................541
					b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)...................................................................................545
				E-6 SWING DOES NOT WORK................................................................................................................................................................547
				E-7 EXCESSIVE HYDRAULIC DRIFT OF SWING ................................................................................................................................................549
				E-8 TRAVEL SPEED DOES NOT SWITCH.......................................................................................................................................................550
					a) SPEED DOES NOT INCREASE WHEN PLACED IN HI (DOES NOT SWITCH TO HI)...............................................................................................................550
					b) SPEED DOES NOT DECREASE WHEN PLACED IN LO.......................................................................................................................................550
				H-1 MACHINE DEVIATES EXCESSIVELY (DEVIATES MORE THAN STANDARD WHEN ONLY TRAVEL SYSTEM IS USED, TRAVEL LEVER AT FULL POSITION)..........................................................556
				H-2 EXCESSIVE DEVIATION IN TRAVEL DURING SIMULTANEOUS OPERATIONS.......................................................................................................................560
				H-3 MACHINE DEVIATES EXCESSIVELY WHEN STARTING.........................................................................................................................................562
				H-4 CONTROL LEVERS ARE EXTREMELY HEAVY.................................................................................................................................................564
					a) IF TRAVEL LEVER IS HEAVY........................................................................................................................................................564
					b) IF WORK EQUIPMENT LEVERS ARE HEAVY..............................................................................................................................................564
				H-5 WORK EQUIPMENT, TRAVEL, AND SWING START SUDDENLY DURING FINE CONTROL OPERATIONS....................................................................................................565
				H-6 SPEEDS FOR WORK EQUIPMENT, SWING, AND TRAVEL ARE ALL EXTREMELY SLOW, OR THERE IS NO POWER..........................................................................................566
					a) MACHINE HARDLY MOVES............................................................................................................................................................566
					b) ABNORMALITY IN SOME PART (ABNORMALITY ON ONE SIDE)..............................................................................................................................568
				H-7 ENGINE STALLS OR ENGINE SPEED DROPS DURING OPERATIONS..............................................................................................................................570
				H-8 NO CHANGE IN OUTPUT WHEN MODE SELECTOR SWITCH IS OPERATED..........................................................................................................................571
				H-9 AUTO-DECELERATION DOES NOT COME ON, OR DOES NOT GO OFF.............................................................................................................................572
				H-10 ABNORMAL NOISE COMES FROM AROUND PUMP.............................................................................................................................................572
				H-11 SWING SPEED IS SLOW, OR OVERRUN WHEN STOPPING SWING IS EXCESSIVE..................................................................................................................573
				H-12 UPPER STRUCTURE DOES NOT SWING....................................................................................................................................................575
				H-13 EXCESSIVE HYDRAULIC DRIFT.........................................................................................................................................................577
				H-16 EXCESSIVE TIME LAG FOR WORK EQUIPMENT.............................................................................................................................................577
				H-17 TRAVEL SPEED DOES NOT SWITCH......................................................................................................................................................578
					a) SPEED DOES NOT INCREASE EVEN WHEN SELECTOR SWITCH IS PLACED IN HI...............................................................................................................578
					b) SPEED DOES NOT DECREASE EVEN WHEN SELECTOR SWITCH IS PLACED IN LO...............................................................................................................578
				FAILURE MODE AND COMPONENTS............................................................................................................................................................579
			W.L MODE TROUBLESHOOTING ..................................................................................................................................................................580
				ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY..............................................................................................................................581
				TROUBLESHOOTING........................................................................................................................................................................582
				W-1 IN ARC DIGGING MODE, WORK EQUIPMENT CARRIES OUT HORIZONTAL DIGGING, OR THERE IS BUCKET ANGLE COMPENSATION..........................................................................584
				W-2 IN HORIZONTAL DIGGING MODE, WORK EQUIPMENT DOES NOT CARRY OUT HORIZONTAL DIGGING...................................................................................................585
					a) SELF-TESTING DISPLAY DOES NOT SHOW ABNORMALITY..................................................................................................................................585
					b) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................587
				W-3 IN HORIZONTAL DIGGING MODE, THERE IS BUCKET ANGLE COMPENSATION.....................................................................................................................593
				W-4 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, WORK EQUIPMENT CARRIES OUT HORIZONTAL DIGGING, BUT THERE IS NO BUCKET ANGLE COMPENSATION...................................594
					a) SELF-TESTING DISPLAY DOES NOT SHOW ABNORMALITY..................................................................................................................................594
					b) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................596
				W-5 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, THERE IS BUCKET ANGLE COMPENSATION, BUT WORK EQUIPMENT DOES NOT CARRY OUT HORIZONTAL DIGGING...............................598
					a) SELF-TESTING DISPLAY DOES NOT SHOW ABNORMALITY..................................................................................................................................598
					b) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................598
				W-6 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, WORK EQUIPMENT DOES NOT CARRY OUT HORIZONTAL DIGGING, AND THERE IS NO BUCKET ANGLE COMPENSATION............................600
					a) SELF-TESTING DISPLAY DOES NOT SHOW ABNORMALITY..................................................................................................................................600
					b) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................601
				L-1 WORK EQUIPMENT DOES NOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION..................................................................................................607
	63 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................................608
		CHARGING AND PTO LUBRICATION PUMP..............................................................................................................................................................609
			REMOVAL AND INSTALLATION...................................................................................................................................................................609
		NO.1 PUMP......................................................................................................................................................................................611
			REMOVAL AND INSTALLATION...................................................................................................................................................................611
		NO.2 PUMP......................................................................................................................................................................................613
			REMOVAL AND INSTALLATION...................................................................................................................................................................613
		MAIN PUMP......................................................................................................................................................................................615
			DISASSEMBLY................................................................................................................................................................................615
			ASSEMBLY...................................................................................................................................................................................619
		SERVO VALVE (FOR NO.1 FRONT PUMP)..............................................................................................................................................................631
			REMOVAL AND INSTALLATION...................................................................................................................................................................631
		SERVO VALVE (FOR NO.1 REAR PUMP)...............................................................................................................................................................631
			REMOVAL AND INSTALLATION...................................................................................................................................................................631
		SERVO VALVE (FOR NO.2 FRONT PUMP)..............................................................................................................................................................631
			REMOVAL AND INSTALLATION...................................................................................................................................................................631
		SERVO VALVE (FOR NO.2 REAR PUMP)...............................................................................................................................................................631
			REMOVAL AND INSTALLATION...................................................................................................................................................................631
		CO・NC VALVE (FOR NO.1 FRONT PUMP)..............................................................................................................................................................633
			REMOVAL AND INSTALLATION...................................................................................................................................................................633
		CO・NC VALVE (FOR NO.1 REAR PUMP)...............................................................................................................................................................633
			REMOVAL AND INSTALLATION...................................................................................................................................................................633
		TVC VALVE......................................................................................................................................................................................635
			REMOVAL AND INSTALLATION...................................................................................................................................................................635
		L.H.5-SPOOL CONTROL VALVE......................................................................................................................................................................637
			REMOVAL....................................................................................................................................................................................637
			INSTALLATION...............................................................................................................................................................................639
		R.H.4-SPOOL CONTROL VALVE......................................................................................................................................................................643
			REMOVAL ...................................................................................................................................................................................643
			INSTALLATION...............................................................................................................................................................................645
		CONTROL VALVE..................................................................................................................................................................................649
			DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................649
		MAIN RELIEF VALVE (FOR L.H.5-SPOOL,R.H.4-SPOOL VALVE)..........................................................................................................................................651
			REMOVAL AND INSTALLATION...................................................................................................................................................................651
		PILOT RELIEF VALVE.............................................................................................................................................................................651
			REMOVAL AND INSTALLATION...................................................................................................................................................................651
		PPC VALVE (FOR TRAVEL).........................................................................................................................................................................653
			REMOVAL AND INSTALLATION...................................................................................................................................................................653
			DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................655
		PPC VALVE (FOR WORK EQUIPMENT AND SWING).......................................................................................................................................................655
			DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................655
		BOOM CYLINDER (BACK HOE).......................................................................................................................................................................657
			REMOVAL AND INSTALLATION...................................................................................................................................................................657
		ARM CYLINDER (BACK HOE)........................................................................................................................................................................659
			REMOVAL AND INSTALLATION...................................................................................................................................................................659
		BUCKET CYLINDER (BACK HOE).....................................................................................................................................................................661
			REMOVAL AND INSTALLATION...................................................................................................................................................................661
		BOOM CYLINDER (LOADING SHOVEL).................................................................................................................................................................663
			REMOVAL AND INSTALLATION...................................................................................................................................................................663
		ARM CYLINDER (LOADING SHOVEL)..................................................................................................................................................................665
			REMOVAL AND INSTALLATION...................................................................................................................................................................665
		BUCKET CYLINDER (LOADING SHOVEL)...............................................................................................................................................................667
			REMOVAL AND INSTALLATION...................................................................................................................................................................667
		BOTTOM DUMP CYLINDER (LOADING SHOVEL)..........................................................................................................................................................669
			REMOVAL AND INSTALLATION...................................................................................................................................................................669
		HYDRAULIC CYLINDER.............................................................................................................................................................................671
			DISASSEMBLY................................................................................................................................................................................671
			ASSEMBLY...................................................................................................................................................................................675
		BUCKET (BACK HOE)..............................................................................................................................................................................679
			REMOVAL AND INSTALLATION...................................................................................................................................................................679
		ARM (BACK HOE).................................................................................................................................................................................681
			REMOVAL AND INSTALLATION...................................................................................................................................................................681
		BOOM (BACK HOE)................................................................................................................................................................................683
			REMOVAL AND INSTALLATION...................................................................................................................................................................683
		BUCKET AND ARM (BACK HOE)......................................................................................................................................................................685
			REMOVAL AND INSTALLATION...................................................................................................................................................................685
		WORK EQUIPMENT (BACK HOE)......................................................................................................................................................................687
			REMOVAL AND INSTALLATION...................................................................................................................................................................687
		BUCKET (LOADING SHOVEL)........................................................................................................................................................................689
			REMOVAL AND INSTALLATION...................................................................................................................................................................689
		ARM (LOADING SHOVEL)...........................................................................................................................................................................691
			REMOVAL AND INSTALLATION...................................................................................................................................................................691
		BOOM (LOADING SHOVEL)..........................................................................................................................................................................693
			REMOVAL AND INSTALLATION...................................................................................................................................................................693
		WORK EQUIPMENT (LOADING SHOVEL)................................................................................................................................................................695
			REMOVAL AND INSTALLATION...................................................................................................................................................................695
		POTENTIOMETER (LOADING SHOVEL).................................................................................................................................................................697
			DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................697
		COUNTERWEIGHT .................................................................................................................................................................................697
			REMOVAL AND INSTALLATION...................................................................................................................................................................697
	64 MAINTENANCE STANDARD............................................................................................................................................................................699
		CHARGING AND PTO LUBRICATION PUMP..............................................................................................................................................................700
		PILOT RELIEF VALVE.............................................................................................................................................................................701
		L.H. 5-SPOOL CONTROL VALVE.....................................................................................................................................................................702
		R.H. 4-SPOOL CONTROL VALVE.....................................................................................................................................................................704
		PPC VALVE......................................................................................................................................................................................706
		PPC SHUTTLE VALVE..............................................................................................................................................................................707
		HYDRAULIC CYLINDER.............................................................................................................................................................................708
		WORK EQUIPMENT.................................................................................................................................................................................712
80 ELECTRIC AND ELECTRONIC SYSTEM......................................................................................................................................................................716
	81 STRUCTURE AND FUNCTION..........................................................................................................................................................................716
		ELECTRICAL WIRING DIAGRAM......................................................................................................................................................................717
		ELECTRICAL CIRCUIT DIAGRAM.....................................................................................................................................................................719
		ELECTRONIC COMPONENTS OF 3-STAGE MODE SELECTOR OLSS............................................................................................................................................723
		ELECTRONIC COMPONENTS OF AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM...............................................................................................................................728
		EVMS...........................................................................................................................................................................................732
	82 TESTING AND ADJUSTING...........................................................................................................................................................................740
		ELECTRICAL CIRCUIT DIAGRAM.....................................................................................................................................................................741
		POSITION OF CONNECTORS FOR TROUBLESHOOTING ....................................................................................................................................................743
		M MODE TROUBLESHOOTING.........................................................................................................................................................................753
			SERIAL NO: 10501-10599.....................................................................................................................................................................755
				M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR...........................................................................................................755
					a) NO DISPLAY APPEARS ON MONITOR PANEL (GAUGES AND MONITOR ITEMS)..................................................................................................................755
					b) DISPLAY OF EITHER GAUGES OR MONITOR ITEMS DOES NOT APPEAR ON MONITOR PANEL......................................................................................................755
					c) DISPLAY DOES NOT APPEAR ON PART OF MONITOR PANEL ASSEMBLY.......................................................................................................................756
				M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT GO OUT...................................................................................................................756
				M-3 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), CHECK BEFORE STARTING ITEM FLASH OR PREHEATING ITEM LIGHTS UP.............................................................757
					a) (COOLANT LEVEL) FLASHES.........................................................................................................................................................757
					b) (ENGINE OIL LEVEL) FLASHES......................................................................................................................................................757
					c) (HYDRAULIC OIL LEVEL) FLASHES...................................................................................................................................................758
					d) (HEATER SIGNAL) FLASHES.........................................................................................................................................................758
				M-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CHECK BEFORE STARTING ITEMS FLASH..............................................................................................760
					a) ALTERNATOR SYSTEM...............................................................................................................................................................760
					b) ENGINE OIL PRESSURE SYSTEM......................................................................................................................................................760
				M-5 WHEN STARTING SWITCH IS TURNED ON, (DO NOT START ENGINE), CAUTION ITEMS FLASH......................................................................................................762
				M-6 WHEN STARTING SWITCH IS ON (ENGINE STARTED), CAUTION ITEMS FLASH...................................................................................................................763
					a) (ENGINE OIL PRESSURE) FLASHES...................................................................................................................................................763
					b) (COOLANT LEVEL) FLASHES.........................................................................................................................................................763
					c) (COOLANT TEMPERATURE GAUGE) FLASHES.............................................................................................................................................764
					d) (CHARGE LEVEL) FLASHES..........................................................................................................................................................764
					e) (HYDRAULIC OIL FILTER) FLASHES..................................................................................................................................................765
					f) (HYDRAULIC OIL TEMPERATURE) FLASHES.............................................................................................................................................766
				M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) FOR 2 SECONDS, OR WHEN CAUTION ITEMS ARE FLASHING, WARNING BUZZER DOES NOT SOUND................................................769
				M-8 NO ABNORMAL DISPLAY ON MONITOR BUT WARNING BUZZER SOUNDS...........................................................................................................................771
				M-9 MONITOR PANEL LAMPS DO NOT LIGHT UP (INDICATION ON MONITOR PANEL IS CORRECT).......................................................................................................772
					a) NO LAMPS ON PANEL LIGHT UP......................................................................................................................................................772
					b) SOME LAMPS ON PANEL DO NOT LIGHT UP.............................................................................................................................................773
				M-10 WHEN ENGINE IS STARTED, SERVICE METER DOES NOT MOVE WHEN ENGINE IS STOPPED, SERVICE METER MOVES...................................................................................775
					a) SERVICE METER DOES NOT MOVE.....................................................................................................................................................775
					b) SERVICE METER DOES NOT STOP MOVING .............................................................................................................................................776
				M-11 ENGINE COOLANT TEMPERATURE IS HIGH, BUT LOWEST LEVEL DISPLAYED....................................................................................................................777
				M-12 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY.................................................................................................................................777
				M-13 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK.................................................................................................................................779
				M-14 NO DISPLAY IS GIVEN FOR FUEL LEVEL................................................................................................................................................779
			SERIAL NO: 10600 AND UP....................................................................................................................................................................781
				M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR...........................................................................................................781
					a) NO DISPLAY APPEARS ON MONITOR PANEL (GAUGE AND MONITOR ITEMS)...................................................................................................................781
					b) DISPLAY DOES NOT APPEAR ON PART OF MONITOR PANEL ASSEMBLY.......................................................................................................................781
				M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT GO OUT...................................................................................................................781
				M-3 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), CHECK BEFORE STARTING ITEM FLASH OR PREHEATING ITEM LIGHTS UP (FLUID LEVEL OF CHECK BEFORE STARTING ITEMS ARE CORRECT)....782
					a) (COOLANT LEVEL) FLASHES.........................................................................................................................................................782
					b) (ENGINE OIL LEVEL) FLASHES......................................................................................................................................................782
					c) (HYDRAULIC OIL LEVEL) FLASHES...................................................................................................................................................783
				M-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CHECK BEFORE STARTING ITEMS FLASH..............................................................................................785
					a) ALTERNATOR SYSTEM...............................................................................................................................................................785
					b) ENGINE OIL PRESSURE SYSTEM......................................................................................................................................................785
				M-5 WHEN STARTING SWITCH IS TURNED ON, (DO NOT START ENGINE), CAUTION ITEMS FLASH......................................................................................................787
				M-6 WHEN STARTING SWITCH IS ON (ENGINE STARTED), CAUTION ITEMS FLASH...................................................................................................................788
					a) (ENGINE OIL PRESSURE) FLASHES...................................................................................................................................................788
					b) (COOLANT LEVEL) FLASHES.........................................................................................................................................................788
					c) (COOLANT TEMPERATURE GAUGE) FLASHES.............................................................................................................................................789
					d) (CHARGE LEVEL) FLASHES..........................................................................................................................................................789
					e) (HYDRAULIC OIL FILTER) FLASHES..................................................................................................................................................790
					f) (HYDRAULIC OIL TEMPERATURE) FLASHES.............................................................................................................................................790
				M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) FOR 1 SECOND, OR WHEN CAUTION ITEMS ARE FLASHING, WARNING BUZZER DOES NOT SOUND.................................................793
				M-8 NO ABNORMAL DISPLAY ON MONITOR BUT WARNING BUZZER SOUNDS...........................................................................................................................793
				M-9 MONITOR PANEL LAMPS DO NOT LIGHT UP (INDICATION ON MONITOR PANEL IS CORRECT).......................................................................................................795
				M-10 WHEN ENGINE IS STARTED, SERVICE METER DOES NOT MOVE WHEN ENGINE IS STOPPED, SERVICE METER MOVES...................................................................................796
					a) SERVICE METER DOES NOT MOVE, WHEN ENGINE IS STARTED.............................................................................................................................796
					b) SERVICE METER DOES NOT STOP MOVING, WHEN ENGINE IS STOPPED......................................................................................................................796
				M-11 ENGINE COOLANT TEMPERATURE IS HIGH, BUT LOWEST LEVEL DISPLAYED....................................................................................................................798
				M-12 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY.................................................................................................................................798
				M-13 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK.................................................................................................................................800
				M-14 NO DISPLAY IS GIVEN FOR FUEL LEVEL................................................................................................................................................800

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KOMATSU PC650-3 PC650LC-3 PC650SE-3 SHOP MANUAL SEBM02090307 – PDF DOWNLOAD

S.S 30/12/24