PDF Service Repair Manual Komatsu PC600-8 PC600LC-8 Hydraulic Excavator - 4 MB
This service repair manual is specifically for the Komatsu PC600-8 and PC600LC-8 hydraulic excavators with serial numbers 30001 and up.
It is the definitive guide for any maintenance or repair work on these powerful machines.
Inside, you will find detailed instructions on diagnostics, testing, disassembly, and assembly of all major components.
The manual includes wiring diagrams and hydraulic schematics to assist technicians in complex troubleshooting.
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--- Page 1 ---
SEN00128-16
HYDRAULIC PC600 -8
EXCAVATOR
PC600LC -8
PC600- 30001
SERIAL NUMBERS and up
PC600LC- 30001
--- Page 3 ---
00 Index and foreword SEN00130-16
E-14 Fuel gauge does not display correctly ................................................................................. 27
E-15 Swing lock monitor does not display correctly ..................................................................... 28
E-16 When monitor switch is operated, nothing is displayed ....................................................... 30
E-17 Wiper and window washer do not work ............................................................................... 32
E-18 "Boom Raise" is not correctly displayed in monitoring function ........................................... 40
E-19 "Boom Lower" is not correctly displayed in monitoring function........................................... 42
E-20 "Arm IN" is not correctly displayed in monitoring function.................................................... 44
E-21 "Arm OUT" is not correctly displayed in monitoring function................................................ 45
E-22 "Bucket CURL" is not correctly displayed in monitoring function ......................................... 46
E-23 "Bucket DUMP" is not correctly displayed in monitoring function ........................................ 47
E-24 "Swing" is not correctly displayed in monitoring function ..................................................... 48
E-25 "Travel" is not correctly displayed in monitoring function ..................................................... 50
E-26 Air conditioner does not work............................................................................................... 52
E-27 Step light does not light up or go off..................................................................................... 54
E-28 Electric grease gun does not operate .................................................................................. 58
E-29 Travel alarm does not sound or does not stop sounding ..................................................... 60
E-30 Horn does not sound............................................................................................................ 62
E-31 Bottom dump does not move ............................................................................................... 64
Troubleshooting of hydraulic and mechanical system (H-mode) SEN00452-02
Before troubleshooting H-mode.................................................................................................... 3
Information in troubleshooting table.............................................................................................. 8
H-1 Speed or power of all work equipment, travel, and swing is low............................................ 10
H-2 Engine speed lowers remarkably or engine stalls.................................................................. 12
H-3 All work equipment, travel, and swing systems do not work.................................................. 14
H-4 Abnormal sound is heard from around pump ........................................................................ 16
H-5 Auto-decelerator is not reset.................................................................................................. 17
H-6 Boom speed or power is low.................................................................................................. 18
H-7 Arm speed or power is low .................................................................................................... 20
H-8 Bucket speed or power is low ................................................................................................ 21
H-9 Boom does not move ............................................................................................................. 22
H-10 Arm does not move.............................................................................................................. 22
H-11 Bucket does not move.......................................................................................................... 23
H-12 Bottom dump does not move ............................................................................................... 23
H-13 Hydraulic drift of work equipment is large ............................................................................ 24
H-14 Time lag of work equipment is large .................................................................................... 25
H-15 Power max. function does not operate or stop .................................................................... 26
H-16 Machine push-up function does not operate or stop............................................................ 26
H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is low .... 27
H-18 When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing,
travel speed is low ............................................................................................................... 27
H-19 When arm and swing are operated simultaneously, swing speed is low ............................. 28
H-20 Machine deviates in one direction ....................................................................................... 29
H-21 Machine deviates largely at start ......................................................................................... 31
H-22 Travel deviation is large during compound operation .......................................................... 32
H-23 Travel speed or power is low ............................................................................................... 33
H-24 Machine does not travel (only one track) ............................................................................. 34
H-25 Travel speed does not change............................................................................................. 35
H-26 Upper structure does not swing ........................................................................................... 36
H-27 Swing speed or acceleration is low...................................................................................... 37
H-28 Upper structure overruns excessively when it stops swinging............................................. 38
H-29 Large shock is made when upper structure stops swinging ................................................ 39
H-30 Large abnormal sound is made when upper structure stops swinging ................................ 40
H-31 Hydraulic drift of swing is large ............................................................................................ 41
Troubleshooting of engine (S-mode) SEN00453-02
Method of using troubleshooting chart ......................................................................................... 3
S-1 Starting performance is poor .................................................................................................. 6
S-2 Engine does not start ............................................................................................................. 8
S-3 Engine does not pick up smoothly ......................................................................................... 12
PC600-8 9
--- Page 4 ---
00 Index and foreword SEN00131-04
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
PC600-8 7
--- Page 5 ---
00 Index and foreword SEN00131-04
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting
electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
PC600-8 17
--- Page 6 ---
00 Index and foreword SEN00131-04
2. Precautions when carrying out installation work
q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation
1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
If any part is loosened or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
If any part is loosened or damaged, retighten or repair it.
PC600-8 27
--- Page 7 ---
00 Index and foreword SEN00131-04
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons
1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC600-8 37
--- Page 8 ---
01 Specification SEN00133-03
Loading shovel specification
PC600-8 PC600LC-8
Working ranges Unit
Loading shovel specification Loading shovel specification
A Max. digging reach mm 9,190 9,190
B Max. digging reach at ground level mm 8,850 8,850
C Max. digging height mm 10,090 10,090
D Max. digging depth mm 3,495 3,495
E Min. digging radius at ground level mm 5,135 5,135
Min. turning radius of work
F mm 5,515 5,515
equipment
PC600-8 5
--- Page 9 ---
01 Specification SEN00133-03
Unit: kg
Machine model PC600-8 PC600LC-8
Serial number 30001 and up 30001 and up
Track shoe assembly
• Standard triple grouser shoe (600 mm) 5,930 6,290
• Wide triple grouser shoe (750 mm) 6,750 7,170
Boom assembly 4,820 4,820
Arm assembly 3,250 3,250
Bucket assembly 2,430 2,430
Boom cylinder assembly 496 × 2 496 × 2
Arm cylinder assembly 734 734
Bucket cylinder assembly 482 482
Link assembly (large) 345 345
Link assembly (small) — —
Boom pin 149 + 26 × 2 + 76 + 104 + 36 149 + 26 × 2 + 76 + 104 + 36
Arm pin 32 + 55 32 + 55
Bucket pin 55 + 62 55 + 62
Link pin 45 × 2 45 × 2
PC600-8 15
--- Page 10 ---
10 Structure, function and maintenance standard SEN00135-02
Unit: mm
No. Check item Criteria Remedy
Backlash between drive gear Standard clearance Clearance limit
8
and driven gear 0.23 – 0.74 —
Backlash of SAL56 pump
9 0.273 – 0.374 — Adjust
input shaft
Backlash between main
10 shaft and connecting hub 0.074 – 0.226 —
assenbly
PC600-8 5
--- Page 11 ---
10 Structure, function and maintenance standard SEN00136-01
Unit: mm
No. Check item Criteria Remedy
Backlash between No. 2 Standard clearance Clearance limit
16
planet carrier and motor 0.06 – 0.21 —
Backlash between No. 2 planet
17 0.21 – 0.69 1.10
gear and No. 2 ring gear
Backlash between No. 1
18 planet gear and No. 1 ring 0.18 – 0.63 1.10
gear
Backlash between No. 2 sun Replace
19 0.17 – 0.62 1.00
gear and No. 2 planet gear
Backlash between No. 1 sun
20 0.14 – 0.45 1.00
gear and No. 1 planet gear
Backlash between No. 1
21 planet carrier and No. 2 sun 0.16 – 0.56 1.00
gear
22 End play of sprocket shaft 0.10 – 0.15 —
Standard size Repair limit Rebuild or
23 Sprocket tooth width
104 101.5 replace
24 Wear of sprocket teeth Repair limit: 6 Replace
PC600-8 7
--- Page 12 ---
10 Structure, function and maintenance standard SEN00137-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installed Installed Free Installed
9 Recoil spring x OD length load length load Replace
292 kN 233.6 kN
859 x 299 715 —
{29,770 kg} {23,816 kg}
Standard
Tolerance Repair limit
size
Top-to-bottom width of idler +4
10 Track frame 163.5 163.5 0 167.5
guide
+1 Rebuild or
Idler support 161 161 0 159
replace
+4
Track frame 329 329 0 334
Left-to-right width of idler
11
guide
Idler support 324 — 322
PC600-8 3
--- Page 13 ---
10 Structure, function and maintenance standard SEN00137-01
Standard shoe
Model
PC600-8 PC600LC-8
Item
Shoe width (mm)
600 600
(triple shoe)
Link pitch (mm) 228.6 228.6
No. of shoes
49 52
(each side)
Selection of track shoe
• Select the most suitable track shoe from the following table
PC600-8 PC600LC-8
Cate- Cate-
Specifications Specifications
gory gory
Standard 600 mm triple A 600 mm triple A
If equipped 700 mm triple B –– ––
If equipped 750 mm triple B 750 mm triple B
If equipped 900 mm triple B 900 mm triple B
Category Use Precautions when using
Rocky ground, • Travel in Lo speed when traveling on rough ground with obstacles such as large
A
normal river soil boulders and fallen trees.
• Cannot be used on rough ground where there are large obstacles such as boulders
Normal soil, soft and fallen trees.
B
land • Travel in Hi speed only on flat ground; when it is impossible to avoid traveling over
obstacles, lower the travel speed to approx. half of Lo speed.
• Use only for ground where “A” and “B” sink and are impossible to use.
Extremely soft • Cannot be used on rough ground where there are large obstacles such as boulders
C ground (swampy and fallen trees
ground) • Travel in Hi speed only on flat ground; when it is impossible to avoid traveling over
obstacles, lower the travel speed to approx. half of Lo speed.
D Paved surface • The shoes are flat, so they have low gradeability
E Paved surface • The shoes are made of rubber, so be careful when traveling on rough ground
a Categories “B” and “C” are wide shoes, so there a When selecting the shoe width, select the nar-
are restrictions on their use. Therefore, before rowest shoe possible within the range that will
using, check the restrictions and consider care- give no problem with flotation and ground pres-
fully the conditions of use before recommending sure.
a suitable shoe width. If necessary, give the cus- If a wider shoe than necessary is used, there will
tomer guidance in their use. be a large load on the shoe, and this may lead
to bending of the shoe, cracking of the links,
breakage of the pins, loosening of the shoe
bolts, or other problems.
PC600-8 13
--- Page 14 ---
10 Structure, function and maintenance standard SEN00138-01
Servo valve
1. Servo valve assembly (No. 1 front)
P1 : Main pump pressure IN port 1. CO+NC valve
PE : TVC valve output pressure front, rear 2. Servo valve
interconnection port
PCO : CO selector pilot port
PD : Jet sensor downstream pressure IN port
PT : Jet sensor upstream pressure IN port
PAC : Servo actuator port
PDR : Servo valve drain OUT port
PPO : Servo basic pressure IN port
PECN : CO+NC valve output pressure output port
PC600-8 9
--- Page 15 ---
10 Structure, function and maintenance standard SEN00138-01
3) When emergency pump drive switch is turned ON and pump load is small
Operation
• If the emergency pump drive switch is turned • Since main pump discharge pressures P1 and