Komatsu PC600 -8E0 Install guide

HYDRAULIC
EXCAVATOR
SEN05377-04
PC600 -8E0
PC600LC-8E0
PC650 -8E0
PC650LC-8E0
PC700LC-8E0
SERIAL NUMBERS
65001
and up

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PC600, 650, 700-8E0 1
(01)
Notice of revision
Notice of revision
4th revision
The affected pages are indicated by the use of the
following marks. It is requested that necessary ac-
tions must be taken to these pages according to the
list below.
2015/06
List of revised pages
Mark Indication Action required
QPage to be newly added Add
qPage to be replaced Replace
( ) Page to be deleted Discard
Mark Page Revision
number Mark Page Revision number Mark Page Revision number Mark Page Revision number
q1 (04) 00-34 01-21 10-34
q2 (04) 00-35 01-22 10-35
3 (01) 00-36 01-23 10-36
4 (01) 00-37 01-24 10-37
q5 (04) 00-38 01-25 10-38
q6 (04) 00-39 01-26 10-39
q7 (04) 00-40 01-27 10-40
8 (01) 00-41 01-28 10-41
00-1 00-42 10-1 10-42
q00-2 (04) 00-43 10-2 10-43
q00-3 (04) 00-44 10-3 10-44
q00-4 (04) 00-45 10-4 10-45
q00-5 (04) 00-46 10-5 10-46
q00-6 (04) 00-47 10-6 10-47
q00-7 (04) 00-48 10-7 10-48
q00-8 (04) 00-49 10-8 10-49
q00-9 (04) 00-50 10-9 10-50
q00-10 (04) 00-51 10-10 10-51
q00-11 (04) 00-52 10-11 10-52
00-12 (03) 00-53 10-12 10-53
00-13 (03) 00-54 10-13 10-54
00-14 (03) 01-1 10-14 10-55
00-15 (03) 01-2 10-15 10-56
00-16 (03) 01-3 10-16 10-57
00-17 01-4 10-17 10-58
00-18 01-5 10-18 10-59
00-19 01-6 10-19 10-60
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00-26 01-13 10-26 10-67
00-27 01-14 10-27 10-68
00-28 01-15 10-28 10-69
00-29 01-16 10-29 10-70
00-30 01-17 10-30 10-71
00-31 01-18 10-31 10-72
00-32 01-19 10-32 10-73
00-33 01-20 10-33 10-74
(04)
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Notice of revision
2PC600, 650, 700-8E0
(01)
10-75 10-127 10-179 20-19
10-76 10-128 10-180 20-20
10-77 10-129 10-181 20-21
10-78 10-130 10-182 20-22
10-79 10-131 10-183 20-23
10-80 10-132 10-184 20-24
10-81 10-133 10-185 20-25
10-82 10-134 10-186 20-26
10-83 10-135 10-187 30-1
10-84 10-136 10-188 30-2
10-85 10-137 10-189 30-3
10-86 10-138 10-190 30-4
10-87 10-139 (01) 10-191 30-5
10-88 10-140 10-192 30-6
10-89 10-141 10-193 30-7
10-90 10-142 10-194 30-8
10-91 10-143 10-195 30-9
10-92 10-144 10-196 30-10
10-93 10-145 10-197 30-11
10-94 10-146 10-198 30-12
10-95 10-147 10-199 30-13
10-96 10-148 10-200 30-14
10-97 10-149 10-201 30-15
10-98 10-150 10-202 30-16
10-99 10-151 10-203 30-17
10-100 10-152 10-204 30-18
10-101 10-153 10-205 30-19
10-102 10-154 10-206 30-20
10-103 10-155 10-207 30-21
10-104 10-156 10-208 30-22
10-105 10-157 10-209 30-23
10-106 10-158 10-210 30-24
10-107 10-159 10-211 30-25
10-108 10-160 10-212 30-26
10-109 q10-161 (04) 20-1 30-27
10-110 10-162 20-2 30-28
10-111 10-163 20-3 30-29
10-112 10-164 20-4 30-30
10-113 10-165 20-5 30-31
10-114 10-166 20-6 30-32
10-115 10-167 20-7 30-33
10-116 10-168 20-8 30-34
10-117 10-169 20-9 30-35
10-118 10-170 20-10 30-36
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10-120 10-172 20-12 30-38
10-121 10-173 20-13 30-39
10-122 10-174 20-14 30-40
10-123 10-175 20-15 30-41
10-124 10-176 20-16 30-42
10-125 10-177 20-17 30-43
10-126 10-178 20-18 30-44
Mark Page Revision
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number Mark Page Revision
number Mark Page Revision
number
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PC600, 650, 700-8E0 3
(01)
Notice of revision
30-45 30-97 40-11 40-63
30-46 30-98 40-12 40-64
30-47 30-99 40-13 40-65
30-48 30-100 40-14 40-66
30-49 30-101 40-15 40-67
30-50 30-102 40-16 40-68
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30-52 30-104 40-18 40-70
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30-88 40-2 40-54 40-106
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30-92 40-6 40-58 40-110
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30-95 40-9 40-61 40-113
30-96 40-10 40-62 40-114
Mark Page Revision
number Mark Page Revision
number Mark Page Revision
number Mark Page Revision
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Notice of revision
4PC600, 650, 700-8E0
(01)
40-115 40-167 40-219 40-271
40-116 40-168 40-220 40-272
40-117 40-169 40-221 40-273
40-118 40-170 40-222 40-274
40-119 40-171 40-223 40-275
40-120 40-172 40-224 40-276
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40-162 40-214 40-266 40-318
40-163 40-215 40-267 40-319
40-164 40-216 40-268 40-320
40-165 40-217 40-269 40-321
40-166 40-218 40-270 40-322
Mark Page Revision
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number Mark Page Revision
number Mark Page Revision
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PC600, 650, 700-8E0 5
(01)
Notice of revision
40-323 40-375 40-427 50-29
40-324 40-376 40-428 50-30
40-325 40-377 40-429 50-31
40-326 40-378 40-430 50-32
40-327 40-379 40-431 50-33
40-328 40-380 40-432 50-34
40-329 40-381 40-433 50-35
40-330 40-382 40-434 50-36
40-331 40-383 40-435 50-37
40-332 40-384 40-436 50-38
40-333 40-385 40-437 50-39
40-334 40-386 40-438 50-40
40-335 40-387 40-439 50-41
40-336 40-388 40-440 50-42
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40-342 40-394 40-446 50-48
40-343 40-395 40-447 50-49
40-344 40-396 40-449 50-50
40-345 40-397 40-449 50-51
40-346 40-398 40-450 50-52
40-347 40-399 50-1 50-53
40-348 40-400 50-2 50-54
40-349 40-401 50-3 50-55
40-350 40-402 50-4 50-56
40-351 40-403 50-5 50-57
40-352 40-404 50-6 50-58
40-353 40-405 50-7 50-59
40-354 40-406 50-8 50-60
40-355 40-407 50-9 50-61
40-356 40-408 50-10 50-62
40-357 40-409 50-11 50-63
40-358 40-410 50-12 50-64
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40-361 40-413 50-15 50-67
40-362 40-414 50-16 50-68
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40-365 40-417 50-19 50-71
40-366 40-418 50-20 50-72
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40-368 40-420 50-22 50-74
40-369 40-421 50-23 50-75
40-370 40-422 50-24 50-76
40-371 40-423 50-25 50-77
40-372 40-424 50-26 50-78
40-373 40-425 50-27 50-79
40-374 40-426 50-28 50-80
Mark Page Revision
number Mark Page Revision
number Mark Page Revision
number Mark Page Revision
number
(04)
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Notice of revision
6PC600, 650, 700-8E0
(01)
50-81 50-133 50-183 50-235
50-82 50-134 50-184 50-236
50-83 50-135 50-185 50-237
50-84 50-136 50-186 50-238
50-85 50-137 50-187 50-239
50-86 50-138 50-188 50-240
q50-87 (04) 50-139 50-189 50-241
q50-88 (04) 50-140 50-190 50-242
50-89 50-141 50-191 50-243
50-90 50-142 50-192 50-244
q50-91 (04) 50-143 50-193 50-245
50-92 50-144 50-194 50-246
q50-93 (04) 50-145 50-195 50-247
50-94 50-146 50-196 50-248
50-95 50-147 50-197 50-249
50-96 50-148 50-198 50-250
50-97 50-149 50-199 50-251
50-98 50-150 50-200 50-252
50-99 50-151 50-201 50-253
50-100 50-152 50-202 50-254
50-101 50-153 50-203 50-255
50-102 50-154 50-204 50-256
50-103 50-155 50-205 50-257
50-104 50-156 50-206 50-258
q50-105 (04) 50-157 50-207 60-1
50-106 50-158 50-208 60-2
50-107 50-159 50-209 60-3
50-108 50-160 50-210 60-4
50-109 50-161 50-211 60-5
50-110 50-162 50-212 60-6
50-111 50-163 50-213 60-7
50-112 50-164 50-214 60-8
50-113 50-165 50-215 60-9
50-114 50-166 50-216 60-10
50-115 50-166-1 (02) 50-217 60-11
50-116 50-166-2 (02) 50-218 60-12
50-117 50-167 50-219 60-13
50-118 50-168 50-220 60-14
50-119 50-169 50-221 60-15
50-120 50-170 50-222 60-16
50-121 50-171 50-223 60-17
50-122 50-172 50-224 60-18
50-123 50-173 50-225 60-19
50-124 50-174 50-226 60-20
50-125 50-175 50-227 60-21
50-126 50-176 50-228 60-22
50-127 50-177 50-229 60-23
50-128 50-178 50-230 60-24
50-129 50-179 50-231 60-25
50-130 50-180 50-232 60-26
50-131 50-181 50-233 60-27
50-132 50-182 50-234 60-28
Mark Page Revision
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number Mark Page Revision
number Mark Page Revision
number
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PC600, 650, 700-8E0 7
(01)
Notice of revision
60-29 60-81 80-51 90-27
60-30 60-82 80-52 90-29
60-31 80-1 80-53 90-31
60-32 80-2 80-54 90-33
60-33 80-3 80-55 90-35
60-34 80-4 80-56 90-37
60-35 80-5 80-57 90-39
60-36 80-6 80-58 90-41
60-37 80-7 80-59 90-43
60-38 80-8 80-60 1
60-39 80-9 80-61 2
60-40 80-10 80-62 3
60-41 80-11 80-63 4
60-42 80-12 80-64 5
60-43 80-13 80-65 6
60-44 80-14 80-66 qColophon (04)
60-45 80-15 80-67
60-46 80-16 80-68
60-47 80-17 80-69
60-48 80-18 80-70
60-49 80-19 80-71
60-50 80-20 80-72
60-51 80-21 80-73
60-52 80-22 80-74
60-53 80-23 80-75
60-54 80-24 80-76
60-55 80-25 80-77
60-56 80-26 80-78
60-57 80-27 80-79
60-58 80-28 80-80
60-59 80-29 80-81
60-60 80-30 80-82
60-61 80-31 80-83
60-62 80-32 80-84
60-63 80-33 90-1
60-64 80-34 90-2
60-65 80-35 90-3
60-66 80-36 90-4
60-67 80-37 90-5
60-68 80-38 90-6
60-69 80-39 90-7
60-70 80-40 90-9
60-71 80-41 90-11
60-72 80-42 90-13
60-73 80-43 90-15
60-74 80-44 90-16
60-75 80-45 90-17
60-76 80-46 90-18
60-77 80-47 90-19
60-78 80-48 90-21
60-79 80-49 90-23
60-80 80-50 90-25
Mark Page Revision
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number Mark Page Revision
number Mark Page Revision
number
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Notice of revision
8PC600, 650, 700-8E0
(01)
Find manuals at https://best-manuals.com

PC600, 650, 700-8E0
SEN0537702-00 00-1
PC600, 650, 700-8E0
Shop Manual
00-1
HYDRAULIC EXCAVATOR
PC600-8E0
PC600LC-8E0
PC650-8E0
PC650LC-8E0
PC700LC-8E0
Machine model Serial number
PC600-8E0 65001 and up
PC600LC-8E0 65001 and up
PC650-8E0 65001 and up
PC650LC-8E0 65001 and up
Machine model Serial number
PC700LC-8E0 65001 and up
00 Index and foreword 00-1
00-1

Table of Contents
PC600, 650, 700-8E0
Table of Contents 00-2
Notice of revision........................................................................................................................ 1
00 Index and foreword
Table of Contents.................................................................................................................... 00- 2
Foreword and general information.......................................................................................... 00- 12
Safety notice ........................................................................................................................ 00- 12
How to read the shop manual.............................................................................................. 00- 17
Explanation of terms for maintenance standard .................................................................. 00- 19
Handling of hydraulic components....................................................................................... 00- 21
Method of disconnecting and connecting push-pull type coupler ........................................ 00- 23
Handling of electric equipment............................................................................................. 00- 26
How to read electric wire code............................................................................................. 00- 36
Precautions when performing work...................................................................................... 00- 39
Standard tightening torque table.......................................................................................... 00- 42
List of abbreviation............................................................................................................... 00- 46
Conversion table.................................................................................................................. 00- 50
01 Specification
Specifications.......................................................................................................................... 01- 4
Specifications drawing......................................................................................................... 01- 4
Working range drawings ...................................................................................................... 01- 6
Specifications....................................................................................................................... 01- 8
Table of weight..................................................................................................................... 01- 18
Table of fuel, coolant and lubricants .................................................................................... 01- 26
10 Structure and function
Engine and cooling system..................................................................................................... 10- 3
Engine related parts............................................................................................................. 10- 3
PTO...................................................................................................................................... 10- 4
Cooling system .................................................................................................................... 10- 5
Power train system ................................................................................................................. 10- 6
Power train........................................................................................................................... 10- 6
Swing circle.......................................................................................................................... 10- 8
Swing machinery.................................................................................................................. 10- 10
Final drive ............................................................................................................................ 10- 12
Undercarriage and frame........................................................................................................ 10- 14
Track frame and idler cushion.............................................................................................. 10- 14
Hydraulic system..................................................................................................................... 10- 16
Hydraulic component layout................................................................................................. 10- 16
Valve control........................................................................................................................ 10- 18
Hydraulic tank and filter ....................................................................................................... 10- 20
Hydraulic pump (piston pump)............................................................................................. 10- 22
Cooling fan pump................................................................................................................. 10- 50
Cooling fan motor................................................................................................................. 10- 58
Control valve........................................................................................................................ 10- 64
Swing motor......................................................................................................................... 10- 80
Travel motor......................................................................................................................... 10- 88
PPC valve............................................................................................................................ 10-109
Solenoid valve...................................................................................................................... 10-117
PPC shuttle valve................................................................................................................. 10-124
Boom drift prevention valve ................................................................................................. 10-125
00-2 (04)

Table of Contents
PC600, 650, 700-8E0
Boom LOWER regeneration valve....................................................................................... 10- 129
Arm regeneration valve........................................................................................................ 10-132
Quick return valve................................................................................................................ 10-135
Line oil filter.......................................................................................................................... 10- 138
Center swivel joint................................................................................................................ 10-139
Accumulator......................................................................................................................... 10-140
Electrical system..................................................................................................................... 10-141
Engine control...................................................................................................................... 10-141
Electrical control system...................................................................................................... 10-151
Monitor system .................................................................................................................... 10-181
KOMTRAX system............................................................................................................... 10-207
Sensors................................................................................................................................ 10- 209
20 Standard value table
Standard value table............................................................................................................... 20- 3
Standard value table for engine........................................................................................... 20- 3
Standard value table for machine........................................................................................ 20- 4
30 Testing and adjusting
Tool for testing, adjusting and troubleshooting....................................................................... 30- 3
Tools for testing, adjusting, and troubleshooting ................................................................. 30- 3
Engine and cooling system..................................................................................................... 30- 7
Testing engine speed .......................................................................................................... 30- 7
Testing intake air pressure (boost pressure) ....................................................................... 30- 9
Testing exhaust gas temperature........................................................................................ 30- 10
Testing exhaust gas color.................................................................................................... 30-11
Testing and adjusting valve clearance................................................................................. 30- 12
Testing compression pressure............................................................................................. 30- 13
Testing blowby pressure...................................................................................................... 30-15
Testing engine oil pressure.................................................................................................. 30-16
Testing EGR valve and bypass valve drive pressure .......................................................... 30- 17
Handling fuel system parts .................................................................................................. 30- 18
Releasing remaining pressure from fuel system.................................................................. 30- 19
Testing fuel pressure ........................................................................................................... 30- 20
Cylinder cut-out test mode................................................................................................... 30-21
No-injection cranking........................................................................................................... 30- 22
Testing fuel return rate and leakage.................................................................................... 30- 23
Bleeding air from fuel circuit ................................................................................................ 30- 26
Testing fuel circuit for leakage............................................................................................. 30-28
Testing and adjusting alternator belt tension....................................................................... 30- 29
Testing and adjusting air conditioner compressor belt tension............................................ 30- 30
Undercarriage and frame........................................................................................................ 30- 31
Testing swing circle bearing clearance................................................................................ 30- 31
Checking and adjusting track tension.................................................................................. 30- 32
Hydraulic system .................................................................................................................... 30- 33
Testing and adjusting oil pressure in work equipment, swing and travel circuits................. 30- 33
Testing and adjusting control circuit oil pressure................................................................. 30- 38
Testing and adjusting control oil pressure of piston pump................................................... 30- 40
Testing servo piston movement........................................................................................... 30- 46
Testing PPC valve output pressure ..................................................................................... 30- 48
Testing output pressure of solenoid valve and PPC shuttle valve....................................... 30- 52
Adjusting play of work equipment and swing PPC vavles ................................................... 30- 58
Isolating the parts causing hydraulic drift in work equipment .............................................. 30- 59
Testing and adjusting travel deviation ................................................................................. 30- 61
(04) 00-3

Table of Contents
PC600, 650, 700-8E0
Testing fan speed ................................................................................................................ 30- 63
Testing fan circuit oil pressure............................................................................................. 30-64
Releasing remaining pressure from hydraulic circuit ........................................................... 30- 65
Testing oil leakage............................................................................................................... 30- 66
Bleeding air from each part.................................................................................................. 30-70
Electrical system..................................................................................................................... 30- 73
Special functions of machine monitor.................................................................................. 30- 73
Handling of voltage circuit of engine controller .................................................................... 30-117
Preparatory work for troubleshooting of electrical system ................................................... 30-118
Inspection procedure of diode.............................................................................................. 30-123
Pm clinic.................................................................................................................................. 30-124
Pm Clinic service ................................................................................................................. 30-124
UNDERCARRIAGE INSPECTION REPORT ...................................................................... 30-136
40 Troubleshooting
General information on troubleshooting.................................................................................. 40- 8
Points to remember when troubleshooting .......................................................................... 40- 8
Sequence of events in troubleshooting................................................................................ 40- 9
Checks before troubleshooting............................................................................................ 40- 10
Classification and procedures for troubleshooting............................................................... 40- 34
Failure codes table............................................................................................................... 40- 37
Symptom and troubleshooting numbers .............................................................................. 40- 41
Information in troubleshooting table..................................................................................... 40- 44
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 46
Connector list and layout ..................................................................................................... 40- 48
Connection table for connector pin numbers....................................................................... 40- 58
T- branch box and T- branch adapter table ......................................................................... 40- 94
Fuse locations...................................................................................................................... 40- 97
Troubleshooting by failure code.............................................................................................. 40-100
Failure code [989L00] Engine Controller Lock Caution 1 .................................................... 40-100
Failure code [989M00] Engine Controller Lock Caution 2 ................................................... 40-101
Failure code [989N00] Engine Controller Lock Caution 3.................................................... 40-102
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-103
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-104
Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40-106
Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40-107
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-108
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-110
Failure code [B@HANS] Hyd Oil Overheat.......................................................................... 40-112
Failure code [CA111] ECM Critical Internal Failure ............................................................. 40-114
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40-116
Failure code [CA122] Chg Air Press Sensor High Error...................................................... 40-118
Failure code [CA123] Chg Air Press Sensor Low Error....................................................... 40-120
Failure code [CA131] Throttle Sensor High Error................................................................ 40-122
Failure code [CA132] Throttle Sensor Low Error................................................................. 40-124
Failure code [CA135] Eng Oil Press Sensor High Error ...................................................... 40-126
Failure code [CA141] Eng Oil Press Sensor Low Error ....................................................... 40-128
Failure code [CA144] Coolant Temp Sens High Error......................................................... 40-130
Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40-132
Failure code [CA153] Chg Air Temp Sensor High Error...................................................... 40-134
Failure code [CA154] Chg Air Temp Sensor Low Error....................................................... 40-136
Failure code [CA187] Sens Supply 2 Volt Low Error........................................................... 40-138
Failure code [CA221] Ambient Press Sens High Error........................................................ 40-140
Failure code [CA222] Ambient Press Sens Low Error......................................................... 40-142
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Table of Contents
PC600, 650, 700-8E0
Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40- 144
Failure code [CA234] Eng Overspeed................................................................................. 40-145
Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40-146
Failure code [CA263] Fuel Temp Sensor High Error........................................................... 40-148
Failure code [CA265] Fuel Temp Sensor Low Error............................................................ 40- 150
Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40-152
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40- 153
Failure code [CA273] PCV2 Short Error.............................................................................. 40-154
Failure code [CA274] PCV2 Open Error.............................................................................. 40-155
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................ 40-156
Failure code [CA323] Inj #5 (L#5) Open/Short Error ........................................................... 40-158
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................ 40-160
Failure code [CA325] Inj #6 (L#6) Open/Short Error ........................................................... 40-162
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................ 40-164
Failure code [CA332] Inj #4 (L#4) Open/Short Error ........................................................... 40-166
Failure code [CA342] Calibration Code Incompatibility ....................................................... 40-168
Failure code [CA351] Injectors Drive Circuit Error............................................................... 40- 169
Failure code [CA352] Sens Supply 1 Volt Low Error........................................................... 40-170
Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40- 172
Failure code [CA441] Battery Voltage Low Error................................................................. 40-172
Failure code [CA442] Battery Voltage High Error................................................................ 40-173
Failure code [CA449] Rail Press Very High Error................................................................ 40-173
Failure code [CA451] Rail Press Sensor High Error............................................................ 40-174
Failure code [CA452] Rail Press Sensor Low Error............................................................. 40-176
Failure code [CA553] Rail Press High Error ........................................................................ 40- 178
Failure code [CA554] Rail Press Sensor In Range Error..................................................... 40-178
Failure code [CA559] Supply Pump Press Low Error 1....................................................... 40- 179
Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40- 182
Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40-184
Failure code [CA757] All Continuous Data Lost Error ......................................................... 40-185
Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40- 186
Failure code [CA1228] EGR Valve Servo Error 1................................................................ 40-188
Failure code [CA1625] EGR Valve Servo Error 2................................................................ 40-189
Failure code [CA1626] BP Valve Sol Current High Error..................................................... 40-190
Failure code [CA1627] BP Valve Sol Current Low Error ..................................................... 40-192
Failure code [CA1628] Bypass Valve Servo Error 1............................................................ 40-194
Failure code [CA1629] Bypass Valve Servo Error 2............................................................ 40-195
Failure code [CA1631] BP Valve Pos Sens High Error ....................................................... 40-196
Failure code [CA1632] BP Valve Pos Sens Low Error ........................................................ 40- 198
Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40- 200
Failure code [CA2185] Throt Sens Sup Volt High Error ...................................................... 40-202
Failure code [CA2186] Throt Sens Sup Volt Low Error....................................................... 40-204
Failure code [CA2249] Rail Press Very Low Error............................................................... 40- 205
Failure code [CA2271] EGR Valve Pos Sens High Error .................................................... 40-206
Failure code [CA2272] EGR Valve Pos Sens Low Error ..................................................... 40- 208
Failure code [CA2351] EGR Valve Sol Current High Error.................................................. 40-210
Failure code [CA2352] EGR Valve Sol Current Low Error .................................................. 40- 212
Failure code [CA2555] Grid Htr Relay Open Circuit Error................................................... 40-214
Failure code [CA2556] Grid Htr Relay Short Circuit Error ................................................... 40-216
Failure code [D110KB] Battery Relay Drive Short Circuit.................................................... 40- 218
Failure code [D163KB] Flash Light Relay Short Circuit....................................................... 40-220
Failure code [D195KA] Step Light Relay Open Circuit ........................................................ 40-222
Failure code [D195KB] Step Light Relay Short Circuit ........................................................ 40-224
Failure code [D19JKZ] Personal code relay abnormality..................................................... 40-226
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Table of Contents
PC600, 650, 700-8E0
Failure code [D862KA] GPS Antenna Open Circuit............................................................. 40-228
Failure code [DA22KK] Pump Solenoid Power Low Error................................................... 40-230
Failure code [DA25KP] 5V Sensor1 Power Abnormality ..................................................... 40-232
Failure code [DA29KQ] Model Selection Abnormality ......................................................... 40-234
Failure code [DA2RMC] CAN Discon (Pump Con Detected)............................................... 40-236
Failure code [DA80MA] Auto. Lub. Abnormal...................................................................... 40-240
Failure code [DAF8KB] Camera Power Supply Short Circuit .............................................. 40-242
Failure code [DAFGMC] GPS Module Error........................................................................ 40-244
Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40-245
Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit.................................................. 40-250
Failure code [DGH2KB] Hyd Oil Sensor Short..................................................................... 40-252
Failure code [DHPAMA] F Pump Press Sensor Abnormality............................................... 40-254
Failure code [DHPBMA] R Pump Press Sensor Abnormality .............................................. 40-256
Failure code [DV20KB] Travel alarm short circuit................................................................ 40-258
Failure code [DW43KA] Travel Speed Sol Open Circuit...................................................... 40-260
Failure code [DW43KB] Travel Speed Sol Short Circuit...................................................... 40-262
Failure code [DW45KA] Swing Brake Sol Open Circuit....................................................... 40-264
Failure code [DW45KB] Swing Brake Sol Short Circuit....................................................... 40-266
Failure code [DW48KA] CO Cancel Sol Open Circuit.......................................................... 40-268
Failure code [DW48KB] CO Cancel Sol Short Circuit.......................................................... 40-270
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol Open Circuit........................................ 40-272
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol Short Circuit........................................ 40-274
Failure code [DW7BKA] Fan Reverse Sol Open Circuit...................................................... 40-276
Failure code [DW7BKB] Fan Reverse Sol Short Circuit ...................................................... 40-278
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit..................................................... 40-280
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit..................................................... 40-282
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit................................................... 40-284
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit ................................................... 40-285
Failure code [DXA0KA] TVC Sol Open Circuit..................................................................... 40-286
Failure code [DXA0KB] TVC Sol Short Circuit..................................................................... 40-288
Failure code [DY20KA] Wiper Working Abnormality............................................................ 40-290
Failure code [DY20MA] Wiper Parking Abnormality ............................................................ 40-294
Failure code [DY2CKA] Washer Drive Open Circuit............................................................ 40-296
Failure code [DY2CKB] Washer Drive Short Circuit............................................................ 40-298
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit..................................................... 40-300
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...................................................... 40-304
Failure code [DY2FMA] Upper Wiper Working Abnormality................................................ 40-308
Failure code [DY2GKM] Wiper Select Abnormality.............................................................. 40-310
Troubleshooting of electrical system (E-mode)....................................................................... 40-314
E-1 Engine does not start (Engine does not crank)............................................................. 40-314
E-2 Preheater does not operate........................................................................................... 40-319
E-3 When starting switch is turned to ON position, machine monitor displays nothing....... 40-323
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up.
............................................................................................................................................. 40-326
E-5 Precaution item lights up while engine is running ......................................................... 40-328
E-6 Emergency stop item lights up while engine is running................................................. 40-330
E-7 Engine coolant temperature gauge does not indicate properly..................................... 40-331
E-8 Fuel gauge does not indicate properly.......................................................................... 40-332
E-9 Hydraulic oil temperature gauge does not indicate properly......................................... 40-334
E-10 Content of display on machine monitor is different from that of actual machine......... 40-336
E-11 Some areas of machine monitor screen are not displayed......................................... 40-336
E-12 Function switch does not operate................................................................................ 40-336
E-13 Automatic warm-up system does not operate (in cold season)................................... 40-337
E-14 Auto-decelerator does not operate properly................................................................ 40-338
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Table of Contents
PC600, 650, 700-8E0
E-15 Working mode does not change ................................................................................. 40-339
E-16 Travel speed does not change.................................................................................... 40- 340
E-17 Alarm buzzer cannot be canceled............................................................................... 40-341
E-18 When starting switch is turned OFF, service meter is not displayed........................... 40-341
E-19 Service mode cannot be selected............................................................................... 40-341
E-20 Any of work equipment, swing and travel does not work or cannot be locked............ 40- 342
E-21 Machine push-up function does not work or cannot be canceled............................... 40- 344
E-22 Boom shockless function does not operate normally.................................................. 40-346
E-23 Swing brake does not operate normally...................................................................... 40-348
E-24 Windshield wiper and window washer do not operate ................................................ 40-350
E-25 Travel alarm does not sound or does not stop sounding ............................................ 40- 353
E-26 BOOM RAISE indicator is not displayed properly with monitoring function................ 40-354
E-27 BOOM LOWER indicator is not displayed properly with monitoring function.............. 40-356
E-28 ARM IN indicator is not displayed properly with monitoring function .......................... 40- 358
E-29 ARM DUMP indicator is not displayed properly with monitoring function ................... 40-360
E-30 BUCKET CURL indicator is not displayed properly with monitoring function.............. 40-362
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function............. 40-364
E-32 Swing indicator is not displayed properly with monitoring function ............................. 40-366
E-33 Travel indicator is not displayed properly with monitoring function............................. 40-368
E-34 "Service" is not displayed normally by monitoring function......................................... 40- 370
E-35 Electric grease gun does not operate ......................................................................... 40-372
E-36 KOMTRAX system does not operate normally ........................................................... 40- 373
E-37 Bottom dump does not operate properly..................................................................... 40-374
E-38 Horn does not sound or does not stop sounding ........................................................ 40- 377
E-39 Step light does not light up or go off............................................................................ 40-380
Troubleshooting of hydraulic and mechanical system (H-mode)............................................ 40-384
Before troubleshooting for hydraulic and mechanical systems............................................ 40-384
Information in troubleshooting table (H-mode) .................................................................... 40-389
H-1 All of work equipment, travel and swing work slow or lack power ................................ 40-390
H-2 Engine speed lowers significantly or engine stalls........................................................ 40- 392
H-3 Any of work equipment, swing and travel does not work.............................................. 40- 394
H-4 Unusual noise is heard from around hydraulic pump.................................................... 40-396
H-5 Auto-decelerator is not canceled .................................................................................. 40- 397
H-6 Speed or power of boom is low..................................................................................... 40-398
H-7 Speed or power of arm is low ....................................................................................... 40- 400
H-8 Speed or power of bucket is low................................................................................... 40- 401
H-9 Boom does not move.................................................................................................... 40- 402
H-10 Arm does not move..................................................................................................... 40-402
H-11 Bucket does not move ................................................................................................ 40-403
H-12 Bottom dump does not move...................................................................................... 40-403
H-13 Hydraulic drift of work equipment is large................................................................... 40- 404
H-14 Time lag of work equipment is large ........................................................................... 40- 405
H-15 One-touch power maximizing function does not work or is not canceled ................... 40-406
H-16 Machine push-up function does not work or is not canceled ...................................... 40-406
H-17 Boom/bucket speed is low at combined operation of arm and boom or bucket.......... 40-406
H-18 Speed of boom, arm, swing and travel is low at combined operation of bucket and boom, arm,
swing and travel................................................................................................................... 40-407
H-19 Swing speed is low at combined operation of arm and swing. ................................... 40-407
H-20 Machine deviates during travel ................................................................................... 40- 408
H-21 Machine deviates significantly at start ........................................................................ 40- 411
H-22 Machine deviates significantly during combined operation......................................... 40- 412
H-23 Travel speed or travel power is low ............................................................................ 40-413
H-24 One of tracks does not run (on one side alone).......................................................... 40-414
H-25 Travel speed does not change.................................................................................... 40-415
(04) 00-7

Table of Contents
PC600, 650, 700-8E0
H-26 Upper structure does not swing .................................................................................. 40-416
H-27 Swing speed is low or acceleration is poor................................................................. 40-417
H-28 Upper structure overruns excessively when it stops swinging.................................... 40-418
H-29 Shock is large when upper structure stops swinging.................................................. 40-419
H-30 Large unusual noise is heard when upper structure stops swinging........................... 40-420
H-31 Hydraulic drift of swing is large ................................................................................... 40-421
Troubleshooting of engine (S-mode) ...................................................................................... 40-422
Method of using troubleshooting chart................................................................................. 40-422
S-1 Startability is poor.......................................................................................................... 40-426
S-2 Engine does not start .................................................................................................... 40-428
S-3 Engine does not pick up smoothly................................................................................. 40-432
S-4 Engine stops during operation....................................................................................... 40-433
S-5 Engine runs rough or is unstable................................................................................... 40-434
S-6 Engine lacks power....................................................................................................... 40-436
S-7 Exhaust smoke is black (incomplete combustion)......................................................... 40-438
S-8 Oil consumption is excessive (or exhaust smoke is blue)............................................. 40-440
S-9 Oil becomes contaminated early................................................................................... 40-441
S-10 Fuel consumption is excessive.................................................................................... 40-442
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) .................................. 40-443
S-12 Oil pressure drops....................................................................................................... 40-444
S-13 Oil level rises (coolant or fuel in oil)............................................................................. 40-446
S-14 Coolant temperature rises too high (overheating)....................................................... 40-448
S-15 Unusual noise is made................................................................................................ 40-449
S-16 Vibration is excessive.................................................................................................. 40-450
50 Disassembly and assembly
General information on disassembly and assembly ............................................................... 50- 4
How to read Disassembly and Assembly............................................................................. 50- 4
Coating materials list............................................................................................................ 50- 6
Special tools list ................................................................................................................... 50- 9
Sketches of special tools ..................................................................................................... 50- 16
Engine and cooling system..................................................................................................... 50- 24
Removal and installation of fuel supply pump assembly ..................................................... 50- 24
Removal and installation of fuel injector assembly .............................................................. 50- 30
Removal and installation of cylinder head assembly........................................................... 50- 33
Removal and installation of radiator assembly .................................................................... 50- 50
Removal and installation of hydraulic oil cooler assembly................................................... 50- 52
Removal and installation of aftercooler assembly................................................................ 50- 54
Removal and installation of engine front seal...................................................................... 50- 56
Removal and installation of engine rear seal....................................................................... 50- 60
Removal and installation of engine, PTO and hydraulic pump assembly............................ 50- 65
Removal and installation of cooling fan motor assembly..................................................... 50- 73
Removal and installation of fuel tank assembly................................................................... 50- 77
Power train.............................................................................................................................. 50- 78
Removal and installation of PTO assembly......................................................................... 50- 78
Disassembly and assembly of PTO assembly..................................................................... 50- 80
Disassembly and assembly of final drive assembly............................................................. 50- 83
Removal and installation of swing motor and swing machinery assembly .......................... 50-106
Disassembly and assembly of swing machinery assembly ................................................. 50-108
Removal and installation of swing circle assembly.............................................................. 50-123
Undercarriage and frame........................................................................................................ 50-124
Separation and connection of track shoe assembly ............................................................ 50-124
Disassembly and assembly of one link in field..................................................................... 50-128
Removal and installation of idler assembly.......................................................................... 50-132
00-8 (04)

Table of Contents
PC600, 650, 700-8E0
Disassembly and assembly of idler assembly ..................................................................... 50-134
Removal and installation of idler cushion assembly ............................................................ 50-141
Disassembly and assembly of idler cushion assembly........................................................ 50- 144
Removal and installation of track roller assembly................................................................ 50-148
Disassembly and assembly of track roller assembly ........................................................... 50-150
Removal and installation of carrier roller assembly............................................................. 50-156
Disassembly and assembly of carrier roller assembly......................................................... 50-158
Removal and installation of revolving frame assembly........................................................ 50- 164
Removal and installation of counterweight assembly.......................................................... 50-166
Removal and installation of counterweight remover assembly............................................ 50-167
Hydraulic system .................................................................................................................... 50-169
Removal and installation of center swivel joint assembly.................................................... 50-169
Disassembly and assembly of center swivel joint assembly................................................ 50- 170
Removal and installation of hydraulic tank assembly .......................................................... 50-172
Removal and installation of hydraulic pump assembly........................................................ 50-174
Removal and installation of control valve assembly............................................................ 50-177
Disassembly and assembly of control valve assembly........................................................ 50- 179
Removal and installation of swing motor assembly............................................................. 50-181
Disassembly and assembly of work equipment PPC valve assembly................................. 50- 182
Disassembly and assembly of travel PPC valve assembly ................................................. 50-184
Disassembly and assembly of grease gun assembly.......................................................... 50-186
Work equipment...................................................................................................................... 50-187
Removal and installation of bucket cylinder assembly ........................................................ 50-187
Removal and installation of arm cylinder assembly............................................................. 50- 191
Removal and installation of boom cylinder assembly.......................................................... 50-195
Removal and installation of bottom dump cylinder assembly.............................................. 50- 199
Removal and installation of bucket assembly...................................................................... 50- 201
Removal and installation of arm assembly.......................................................................... 50-205
Removal and installation of boom assembly ....................................................................... 50-208
Removal and installation of work equipment assembly....................................................... 50-212
Disassembly and assembly of work equipment cylinder assembly ..................................... 50-216
Cab and its attachments......................................................................................................... 50-222
Removal and installation of operator's cab assembly.......................................................... 50- 222
Removal and installation of operator's cab glass (adhered window glass).......................... 50-226
Removal and installation of front window assembly............................................................ 50-236
Removal and installation of air conditioner unit assembly................................................... 50- 243
Electrical system..................................................................................................................... 50-247
Removal and installation of air conditioner compressor assembly...................................... 50-247
Removal and installation of air conditioner condenser assembly........................................ 50- 250
Removal and installation of engine controller assembly...................................................... 50- 252
Removal and installation of pump controller assembly........................................................ 50- 254
Removal and installation of KOMTRAX terminal assembly................................................. 50- 256
Removal and installation of machine monitor assembly...................................................... 50- 257
60 Maintenance standard
Engine and cooling system..................................................................................................... 60- 3
Engine mount....................................................................................................................... 60- 3
PTO ..................................................................................................................................... 60- 5
Cooling system.................................................................................................................... 60- 6
Power train.............................................................................................................................. 60- 7
Swing circle.......................................................................................................................... 60- 7
Swing machinery ................................................................................................................. 60- 8
Final drive ............................................................................................................................ 60- 10
Sprocket............................................................................................................................... 60- 12
(04) 00-9

Table of Contents
PC600, 650, 700-8E0
Undercarriage and frame........................................................................................................ 60- 16
Track frame and idler cushion.............................................................................................. 60- 16
Idler...................................................................................................................................... 60- 18
Track roller........................................................................................................................... 60- 22
Carrier roller......................................................................................................................... 60- 25
Track shoe ........................................................................................................................... 60- 28
Hydraulic system..................................................................................................................... 60- 38
Hydraulic pump.................................................................................................................... 60- 38
Control valve........................................................................................................................ 60- 48
Swing motor......................................................................................................................... 60- 54
Travel motor......................................................................................................................... 60- 55
PPC valve............................................................................................................................ 60- 58
Boom drift prevention valve ................................................................................................. 60- 65
Regeneration valve (boom, arm) ......................................................................................... 60- 66
Center swivel joint................................................................................................................ 60- 67
Work equipment...................................................................................................................... 60- 68
Work equipment................................................................................................................... 60- 68
Work equipment dimension ................................................................................................. 60- 72
Work equipment cylinder ..................................................................................................... 60- 78
80 Appendix
Air conditioner......................................................................................................................... 80- 3
Precautions for refrigerant ................................................................................................... 80- 3
Air conditioner component................................................................................................... 80- 4
Configuration and function of refrigeration cycle.................................................................. 80- 6
Outline of refrigeration cycle................................................................................................ 80- 7
Air conditioner unit............................................................................................................... 80- 10
Air conditioner controller...................................................................................................... 80- 15
Compressor ......................................................................................................................... 80- 16
Condenser ........................................................................................................................... 80- 17
Receiver drier....................................................................................................................... 80- 18
Procedure for testing and troubleshooting........................................................................... 80- 20
Circuit diagram and arrangement of connector pins............................................................ 80- 22
System diagram................................................................................................................... 80- 24
Detail of air conditioner unit ................................................................................................. 80- 26
Parts and connectors layout ................................................................................................ 80- 28
Testing air leakage (duct) .................................................................................................... 80- 31
Testing with self-diagnosis function..................................................................................... 80- 32
Testing temperature control................................................................................................. 80- 35
Testing vent (mode) changeover......................................................................................... 80- 37
Testing FRESH/RECIRC air changeover ............................................................................ 80- 40
Testing inner sensor ............................................................................................................ 80- 42
Testing evaporator temperature sensor............................................................................... 80- 43
Testing sunlight sensor........................................................................................................ 80- 45
Testing (dual) pressure switch for refrigerant ...................................................................... 80- 46
Testing relays....................................................................................................................... 80- 47
Troubleshooting chart 1 ....................................................................................................... 80- 48
Troubleshooting chart 2 ....................................................................................................... 80- 50
Information in troubleshooting table..................................................................................... 80- 52
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
............................................................................................................................................. 80- 54
Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80- 59
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)......... 80- 63
Troubleshooting for temperature control.............................................................................. 80- 67
00-10 (04)