Komatsu PC600-8, PC600LC-8 30001 & Up SEN00128-15 (Preview)
COVER
00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
01 Specification
Specification and technical data
Specification and technical data
Specification drawings
Working range drawings
Specifications
Weight table
Table of fuel, coolant and lubricants
10 Structure, function and maintenance standard
Engine and cooling system
Engine and cooling system
Parts related to engine
PTO
Fan, control and PTO lubrication pump
Radiator, oil cooler
Power train
Power train
Power train
Final drive
Sprocket
Swing circle
Swing machinery
Undercarriage and frame
Undercarriage and frame
Track frame, recoil spring
Idler
Carrier roller
Track roller
Track shoe
Hydraulic system, Part 1
Hydraulic system, Part 1
Hydraulic piping drawing
Hydraulic tank, hydraulic filter
Hydraulic pump (piston pump)
Line oil filter
Cooling fan pump
Cooling fan motor
Hydraulic system, Part 2
Hydraulic system, Part 2
Control valve
Swing motor
Swing brake
Safety valve
Reverse prevention valve
Center swivel joint
Travel motor
Parking brake
Brake valve
Set pressures varying mechanism
Valve control
Work equipment, swing PPC valve
Travel PPC valve
Service PPC valve
PPC accumulator
PPC shuttle valve
Solenoid valve
Boom holding valve
Boom LOWER regeneration valve
Quick return valve
Hydraulic cylinder
Work equipment
Work equipment
Work equipment
Dimensions of work equipment
Cab and its attachments
Cab and its attachments
Air conditioner piping
Electrical system
Engine control
Machine control system diagram
Monitor system
Sensors
KOMTRAX system
20 Standard value table
Standard service value table
Standard value table for engine
Standard value table for chassis
30 Testing and adjusting
Testing and adjusting, Part 1
Tools for testing, adjusting and troubleshooting
Measuring engine speed
Measuring intake air pressure (boost pressure)
Measuring exhaust gas temperature
Measuring exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Testing EGR valve and bypass valve drive oil pressure
Handling equipment in fuel circuit
Releasing remaining pressure in fuel system
Measuring fuel pressure
Reduced cylinder mode operation
No-injection cranking
Testing leakage from pressure limiter and return rate from injector
Bleeding air from fuel circuit
Testing fuel system for leakage
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Testing clearance of swing circle bearing
Testing and adjusting track shoe tension
Testing and adjusting work equipment, swing, and travel circuit oil pressures
Testing and adjusting control circuit oil pressure
Testing and adjusting piston pump control oil pressure
Testing servo piston stroke
Measuring PPC valve output pressure
Measuring outlet pressures of solenoid valve and PPC shuttle valve
Adjusting work equipment, swing PPC valve
Testing and adjusting travel deviation
Measuring fan speed
Measuring fan circuit oil pressure
Inspection of locations of hydraulic drift of work equipment
Measuring oil leakage
Releasing remaining pressure in hydraulic circuit
Bleeding air from each part
Inspection procedures for diode
Testing and adjusting, Part 2
Special function of machine monitor
Handling controller voltage circuit
Procedure for turning on KOMTRAX terminal
KOMTRAX terminal lamp indications
Preparation work for troubleshooting electrical system
Adjusting mirrors
Pm-clinic service
Undercarriage inspection
40 Troubleshooting
Failure code table and fuse locations
Failure codes table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures of troubleshooting
Information contained in troubleshooting table
Failure-looking phenomenon and troubleshooting No.
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code (Display of code), Part 1
Failure code [A000N1] Eng. Hi Out of Std
Failure code [AA10NX] Aircleaner clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Eng. Oil Press. Low
Failure code [B@BAZK] Eng. Oil Level Low
Failure code [B@BCNS] Eng. Water Overheat
Failure code [B@BCZK] Eng. Water Lvl Low
Failure code [B@HANS] Hydr. Oil Overheat
Failure code [CA111] ECM Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA135] Eng Oil Press Sensor High Error
Failure code [CA141] Eng Oil Press Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA263] Fuel Temp Sensor High Error
Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA273] PCV2 Short Error
Failure code [CA274] PCV2 Open Error
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA322] Inj #1 (L#1) Open/Short Error
Failure code [CA323] Inj #5 (L#5) Open/Short Error
Failure code [CA324] Inj #3 (L#3) Open/Short Error
Failure code [CA325] Inj #6 (L#6) Open/Short Error
Failure code [CA331] Inj #2 (L#2) Open/Short Error
Failure code [CA332] Inj #4 (L#4) Open/Short Error
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA554] Rail Press Sensor In Range Error
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Persistent Data Lost Error
Failure code [CA778] Engine Bkup Speed Sensor Error
Failure code [CA1228] EGR Valve Servo Error 1
Failure code [CA1625] EGR Valve Servo Error 2
Failure code [CA1626] BP Valve Sol Current High Error
Failure code [CA1627] BP Valve Sol Current Low Error
Failure code [CA1628] Bypass Valve Servo Error 1
Failure code [CA1629] Bypass Valve Servo Error 2
Failure code [CA1631] BP Valve Pos Sens High Error
Failure code [CA1632] BP Valve Pos Sens Low Error
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA1642] EGR Inlet Press Sens Low Error
Failure code [CA1653] EGR Inlet Press Sens High Error
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2351] EGR Valve Sol Current High Error
Failure code [CA2352] EGR Valve Sol Current Low Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Troubleshooting by failure code (Display of code), Part 3
Failure code [D110KB] Battery Relay Drive S/C
Failure code [D163KB] Flash Light Relay S/C
Failure code [D195KB] Step Light Relay S/C
Failure code [DA25KP] Press. Sensor Power Abnormality
Failure code [DA2SKQ] Model Selection Abnormality
Failure code [DA80MA] Auto. Lub Abnormal
Failure code [DA2RMC] Pump Comm. Abnormality
Failure code [DAFRMC] Monitor Comm. Abnormality
Failure code [DGE5KY] Ambi. Temp. Sensor S/C
Failure code [DGE5KY] Ambi. Temp. Sensor S/C
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C
Failure code [DHPAMA] F pump P. Sensor Abnormality
Failure code [DHPBMA] R pump P. Sensor Abnormality
Failure code [DV20KB] Travel Alarm S/C
Failure code [DW43KA] Travel Speed Sol. Disc.
Failure code [DW43KB] Travel Speed Sol. S/C
Failure code [DW45KA] Swing Brake Sol. Disc.
Failure code [DW45KB] Swing Brake Sol. S/C
Failure code [DW48KA] CO Cancel Sol. Disc.
Failure code [DW48KB] CO Cancel Sol. S/C
Failure code [DW7BKA] Fan Reverse Sol. Disc.
Failure code [DW7BKB] Fan Reverse Sol. S/C
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc.
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C
Failure code [DWK0KA] 2-stage Relief Sol. Disc.
Failure code [DWK0KB] 2-stage Relief Sol. S/C
Failure code [DX16KA] Fan Pump EPC Sol. Disc.
Failure code [DX16KB] Fan Pump EPC Sol. S/C
Failure code [DXA0KA] TVC Sol. Disc.
Failure code [DXA0KB] TVC Sol. S/C
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive S/C
Failure code [DY2DKB] Wiper Drive (For) S/C
Failure code [DY2EKB] Wiper Drive (Rev) S/C
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not rotate)
E-2 Preheater does not operate
E-3 Auto engine warm-up device does not work
E-4 Auto-decelerator does not operate
E-5 All work equipment, swing and travel do not move
E-6 Power max. function does not operate
E-7 Machine push-up function does not operate normally
E-8 Any item is not displayed on machine monitor
E-9 Part of display on machine monitor is missing
E-10 Machine monitor displays contents irrelevant to the model
E-11 Fuel level monitor red lamp lights up while engine is running
E-12 Engine coolant temperature gauge does not display correctly
E-13 Hydraulic oil temperature gauge does not display correctly
E-14 Fuel gauge does not display correctly
E-15 Swing lock monitor does not display correctly
E-16 When monitor switch is operated, nothing is displayed
E-17 Wiper and window washer do not work
E-18 “Boom Raise” is not correctly displayed in monitoring function
E-19 “Boom Lower” is not correctly displayed in monitoring function
E-20 “Arm IN” is not correctly displayed in monitoring function
E-21 “Arm OUT” is not correctly displayed in monitoring function
E-22 “Bucket CURL” is not correctly displayed in monitoring function
E-23 “Bucket DUMP” is not correctly displayed in monitoring function
E-24 “Swing” is not correctly displayed in monitoring function
E-25 “Travel” is not correctly displayed in monitoring function
E-26 Air conditioner does not work
E-27 Step light does not light up or go off
E-28 Electric grease gun does not operate
E-29 Travel alarm does not sound or does not stop sounding
E-30 Horn does not sound
E-31 Bottom dump does not move
Troubleshooting of hydraulic and mechanical system (H-mode)
Before troubleshooting H-mode
Information in troubleshooting table
H-1 Speed or power of all work equipment, travel, and swing is low
H-2 Engine speed lowers remarkably or engine stalls
H-3 All work equipment, travel, and swing systems do not work
H-4 Abnormal sound is heard from around pump
H-5 Auto-decelerator is not reset
H-6 Boom speed or power is low
H-7 Arm speed or power is low
H-8 Bucket speed or power is low
H-9 Boom does not move
H-10 Arm does not move
H-11 Bucket does not move
H-12 Bottom dump does not move
H-13 Hydraulic drift of work equipment is large
H-14 Time lag of work equipment is large
H-15 Power max. function does not operate or stop
H-16 Machine push-up function does not operate or stop
H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is low
H-18 When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel speed is low
H-19 When arm and swing are operated simultaneously, swing speed is low
H-20 Machine deviates in one direction
H-21 Machine deviates largely at start
H-22 Travel deviation is large during compound operation
H-23 Travel speed or power is low
H-24 Machine does not travel (only one track)
H-25 Travel speed does not change
H-26 Upper structure does not swing
H-27 Swing speed or acceleration is low
H-28 Upper structure overruns excessively when it stops swinging
H-29 Large shock is made when upper structure stops swinging
H-30 Large abnormal sound is made when upper structure stops swinging
H-31 Hydraulic drift of swing is large
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lacks output (or lacks power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant or fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
50 Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system, Part 1
Removal and installation of fuel supply pump assembly
Removal and installation of cylinder head assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Engine and cooling system, Part 2
Removal and installation of engine, PTO and hydraulic pump assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of fan motor assembly
Removal and installation of fuel tank assembly
Power train
Removal and installation of PTO assembly
Disassembly and assembly of PTO assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Disassembly and assembly of final drive assembly
Undercarriage and frame
Removal and installation of track shoe assembly
Disassembly and assembly of 1 link in field
Removal and installation of idler, recoil spring assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Removal and installation of counterweight remover assembly
Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of hydraulic pump assembly
Removal and installation of control valve and solenoid valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of main control valve assembly
Removal and installation of swing motor assembly
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of grease gun assembly
Work equipment
Removal and installation of bucket cylinder assembly (Backhoe specification)
Removal and installation of bucket cylinder assembly (Loading shovel specification)
Removal and installation of arm cylinder assembly (Backhoe specification)
Removal and installation of arm cylinder assembly (Loading shovel specification)
Removal and installation of boom cylinder assembly (Backhoe specification)
Removal and installation of boom cylinder assembly (Loading shovel specification)
Removal and installation of bottom dump cylinder assembly (Loading shovel specification)
Removal and installation of bucket assembly (Backhoe specification)
Removal and installation of bucket assembly (Loading shovel specification)
Removal and installation of arm assembly (Backhoe specification)
Removal and installation of arm assembly (Loading shovel specification)
Removal and installation of boom assembly (Backhoe specification)
Removal and installation of boom assembly (Loading shovel specification)
Removal and installation of work equipment (Backhoe specification)
Removal and installation of work equipment (Loading shovel specification)
Cab and its attachments
Removal and installation of operator’s cab
Removal and installation of operator’s cab glass (stuck glass)
Removal and installation of front window assembly
Electrical system
Removal and installation of air conditioner unit assembly
Removal and installation of engine controller assembly
Removal and Installation of KOMTRAX terminal assembly
Removal and installation of pump controller assembly
Removal and installation of monitor assembly
90 Diagrams and drawings
Hydraulic diagrams and drawings
Hydraulic circuit diagram (1/4) (Backhoe specification)
Hydraulic circuit diagram (2/4) (ATT specification)
Hydraulic circuit diagram (3/4) (Loading shovel specification)
Hydraulic circuit diagram (4/4) (Loading shovel specification)
Electrical diagrams and drawings
Electrical circuit diagram (1/6)
Electrical circuit diagram (2/6)
Electrical circuit diagram (3/6)
Electrical circuit diagram (4/6)
Electrical circuit diagram (5/6)
Electrical circuit diagram (6/6)
Connector arrangement diagram
Electrical circuit diagram for air conditioner
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