Komatsu PC650-5, PC710-5 Hydraulic Excavator Service Repair Shop Manual - SEBM000607

This Complete Service Repair Workshop Manual PDF Download for the PC650-5, PC650SE-5, PC650LC-5, PC710-5, PC710SE-5 Komatsu Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu PC650-5 - S/N: 20001 and up
Komatsu PC650SE-5 - S/N: 20001 and up
Komatsu PC650LC-5 - S/N: 20001 and up
Komatsu PC710-5 - S/N: 10001 and up
Komatsu PC710SE-5 - S/N: 10001 and up


TABLE OF CONTENTS :

- GENERAL
- STRUCTURE AND FUNCTION
- TESTING AND ADJUSTING
- DISASSEMBLY AND ASSEMBLY
- MAINTENANCE STANDARD
- OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM000607
Total Pages : 734


This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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CONTENTS

01 GENERAL
ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND WATER

10 STRUCTURE AND FUNCTION
PTO (POWER TAKE-OFF)
PTO LUBRICATION SYSTEM
RADIATOR AND OIL COOLER
POWER TRAIN
SWING MACHINERY
SWING CIRCLE
FINAL DRIVE
TRACK FRAME
IDLER CUSHION
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK SHOE
AIR PIPING
AIR CIRCUIT DIAGRAM
AIR COMPRESSOR
AIR GOVERNOR
AIR TANK
SAFETY VALVE
HORN VALVE
GREASE PUMP
HYDRAULIC UNIT LOCATION
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC TANK
NO.1 PUMP
NO.2 PUMP
SWING PUMP
CHARGING AND PTO LUBRICATING PUMP
LINE OIL FILTER
PILOT OIL FILTER
RETURN OIL FILTER
DRAIN OIL FILTER
L.H. 5-SPOOL CONTROL VALVE
R.H. 4-SPOOL CONTROL VALVE
SWING CONTROL VALVE
SWING MOTOR
CENTER SWIVEL JOINT
TRAVEL MOTOR
CONTROL RELIEF VALVE
SAFETY LOCK VALVE
ACCUMULATOR
PPC VALVE
SOLENOID VALVE ASSEMBLY
EPC VALVE
AUTO-DECELERATION CYLINDER
PPC SHUTTLE VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT
ELECTRICAL WIRING DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
ENGINE CONTROL
MACHINE CONTROL SYSTEM
WORK EQUIPMENT CONTROL SYSTEM
MACHINE MONITORING SYSTEM

20 TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
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
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING FAN BELT TENSION
ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING ENGINE SPEED SENSOR
CHECKING SWING CIRCLE BEARING CLEARANCE
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, TRAVEL CIRCUIT PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE
MEASURING STROKE OF SERVO PISTON
TESTING AND ADJUSTING TRAVEL DEVIATION
MEASURING OIL LEAKAGE
CHECKING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
MEASURING PPC VALVE OUTPUT PRESSURE
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
MEASURING SOLENOID VALVE OUTLET PRESSURE
BLEEDING AIR
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
POSITION OF CONNECTORS FOR TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
SELF-DIAGNOSTIC DISPLAY OF CONTROLLERS
METHOD OF USING JUDGEMENT TABLE
METHOD OF USING TROUBLESHOOTING CHART
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM OR HYDRAULIC, MECHANICAL SYSTEM
E-1. EXCESSIVE DEVIATION WHEN TRAVEL (CONSTANT DEVIATION)
E-2. SPEED OF WORK EQUIPMENT, SWING, TRAVEL IS EXTREMELY SLOW OR LACKS POWER
E-3. ENGINE STALLS DURING OPERATIONS, OR ENGINE SPEED DROPS
E-4. EVEN WHEN MODE SELECTOR SWITCH IS SWITCHED, OUTPUT DOES NOT CHANGE
E-5. AUTO-DECELERATION FUNCTION DOES NOT WORK PROPERLY (THERE IS NO DECELERATION, OR DECELERATION STAYS ON)
E-6. UPPER STRUCTURE DOES NOT SWING
E-7. EXCESSIVE HYDRAULIC DRIFT OF SWING
E-8. TRAVEL SPEED DOES NOT CHANGE
E-9. EXCESSIVE TRAVEL DEVIATION DURING COMPOUND OPERATIONS (BUT ONLY FOR COMBINATION OF TRAVEL AND WORK EQUIPMENT)
E-10. DEFECTIVE OPERATION OF HEAVY LIFT FUNCTION
E-11. MACHINE PUSH UP FUNCTION IS NOT ACTUATED
E-12. ENGINE DOES NOT START
E-13. ENGINE DOES NOT STOP
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTME (H MODE)
H-1. EXCESSIVE TRAVEL DEVIATION (GOES OUTSIDE STANDARD ONLY DURING TRAVEL OPERATIONS, WHEN TRAVEL LEVER IS OPERATED TO END OF STROKE)
H-2. EXCESSIVE TRAVEL DEVIATION DURING COMPOUND OPERATIONS
H-3. EXCESSIVE DEVIATION WHEN STARTING
H-4. CONTROL LEVERS ARE EXTREMELY HEAVY
H-5. WORK EQUIPMENT, TRAVEL, SWING START TO MOVE SUDDENLY (IN FINE CONTROL RANGE)
H-6. SPEED OF WORK EQUIPMENT, SWING, TRAVEL IS EXTREMELY SLOW OR LACKS POWER
H-7. ENGINE STALLS OR ENGINE SPEED DROPS DURING OPERATION
H-8. OUTPUT DOES NOT CHANGE WHEN MODE SELECTOR SWITCH IS OPERATED
H-9. AUTO-DECELERATION FUNCTION DOES NOT WORK PROPERLY (THERE IS NO DECELERATION OR DECELERATION STAYS ON )
H-10. ABNORMAL NOISE COMES FROM AROUND PUMP
H-11. SWING SPEED IS SLOW, OR THERE IS EXCESSIVE OVERRUN WHEN STOPPING SWING
H-12. UPPER STRUCTURE DOES NOT SWING
H-13. EXCESSIVE HYDRAULIC DRIFT OF SWING
H-14. EXCESSIVE HYDRAULIC DRIFT OF WORK EQUIPMENT
H-15. EXCESSIVE TIME LAG OF WORK EQUIPMENT
H-16. TRAVEL SPEED DOES ONT CHANGE
H-17. DEFECTIVE ACTUATION OF HEAVY-LIFT FUNCTION (BOOM RAISE SET PRESSURE DOES NOT INCREASE, OR INCREASES BUT DOES NOT GO DOWN)
H-18. DEFECTIVE ACTUATION OF MACHINE PUSH UP FUNCTION (BOOM LOWER SET PRESSURE DOES NOT INCREASE, OR INCRESES BUT DOES NOT GO DOWN)
TABLE OF FAILURE MODES AND CAUSES
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)
M-1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
M-2. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT GO OUT
M-3. WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH. (FLUID LEVEL OF CHECK ITEMS ARE CORRECT)
M-4. WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH
M-5. WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH
M-6. WHEN STARTING SWITCH IS TURNED ON AMD ENGINE IS STARTED, CAUTION ITEMS FLASH
M-7. WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) FOR 1 SECOND, OR WHEN CAUTION ITEMS ARE FLASHING, WARNING BUZZER DOES NOT SOUND
M-8. NO ABNORMAL DISPLAY ON MONITOR BUT WARNING BUZZER SOUNDS
M-9. PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)
M-10. WHEN ENGINE IS STARTED, SERVICE METER DOES NOT MOVE, WHEN ENGINE IS STOPPED, SERVICE METER MOVES
M-11. COOLANT TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE
M-12. COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY
M-13. FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL
M-14. FUEL LEVEL GAUGE GIVES NO DISPLAY
M-15. HEAD LAMP, WORKING LAMP DO NOT LIGHT UP
M-16. WIPERS DO NOT WORK

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
NOZZLE HOLDER
REMOVAL
INSTALLATION
ENGINE OIL COOLER
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP
REMOVAL AND INSTALLATION
WATER PUMP
REMOVAL AND INSTALLATION
TURBOCHARGER
REMOVAL AND INSTALLATION
HYRDAULIC COOLER
REMOVAL AND INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
RADIATOR
REMOVAL AND INSTALLATION
AFTER-COOLER CORE
REMOVAL AND INSTALLATION
ENGINE, PTO, HYDRAULIC PUMP
REMOVAL
INSTALLATION
PTO
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
FINAL DRIVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
REVOLVING FRAME
REMOVAL
INSTALLATION
SWING MACHINERY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
SWING CIRCLE
REMOVAL AND INSTALLATION
TRACK SHOE
REMOVAL
INSTALLATION
ONE LINK
FIELD DISASSEMBLY
FIELD ASSEMBLY
SPROCKET
REMOVAL AND INSTALLATION
IDLER
REMOVAL AND INSTALLATION
FRONT IDLER
DISASSEMBLY
ASSEMBLY
IDLER ADJUSTMENT CYLINDER
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK ROLLER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
NO.1 PUMP
REMOVAL
INSTALLATION
HYDRAULIC PUMP
DISASSEMBLY
ASSEMBLY
SERVO VALVE
REMOVAL AND INSTALLATION
TVC VALVE
REMOVAL AND INSTALLATION
CO・NC VALVE
REMOVAL AND INSTALLATION
NO.2 PUMP
REMOVAL
INSTALLATION
SWING PUMP
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
CHARGING, PTO LUBRICATION PUMP
REMOVAL AND INSTALLATION
MAIN RELIEF VALVE (FOR SWING CONTROL VALVE)
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
MAIN CONTROL VALVE (FOR WORK EQUIPMENT,4-,5-SPOOL CONTROL VALVE)
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
SWING CONTROL VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
CONTROL VALVE (WORK EQUIPMENT)
DISASSEMBLY
ASSEMBLY
SWING MOTOR
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
CENTER SWIVEL JOINT
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
TRAVEL MOTOR
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
CHARGING PUMP RELIEF VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
PPC VALVE (FOR TRAVEL)
DISASSEMBLY AND ASSEMBLY
PPC VALVE (FOR WORK EQUIPMENT, SWING)
DISASSEMBLY AND ASSEMBLY
AUTO-DECELERATION CYLINDER
REMOVAL AND INSTALLATION
BOOM CYLINDER (BACK HOE)
REMOVAL
INSTALLATION
ARM CYLINDER (BACK HOE)
REMOVAL AND INSTALLATION
BUCKET CYLINDER (BACK HOE)
REMOVAL
INSTALLATION
BOOM CYLINDER (LOADING SHOVEL)
REMOVAL
INSTALLATION
ARM CYLINDER (LOADING SHOVEL)
REMOVAL
INSTALLATION
BUCKET CYLINDER (LOADING SHOVEL)
REMOVAL
INSTALLATION
BOTTOM, DUMP CYLINDER (LOADING SHOVEL)
REMOVAL AND INSTALLATION
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
BUCKET (BACK HOE)
REMOVAL AND INSTALLATION
ARM (BACK HOE)
REMOVAL
INSTALLATION
BOOM (BACK HOE)
REMOVAL AND INSTALLATION
BUCKET AND ARM (BACK HOE)
REMOVAL AND INSTALLATION
WORK EQUIPMENT (BACK HOE)
REMOVAL
INSTALLATION
BUCKET (LOADING SHOVEL)
REMOVAL AND INSTALLATION
ARM (LOADING SHOVEL)
REMOVAL
INSTALLATION
BOOM (LOADING SHOVEL)
REMOVAL
INSTALLATION
WORK EQUIPMENT (LOADING SHOVEL)
REMOVAL
INSTALLATION
OPERATOR'S CAB
REMOVAL AND INSTALLATION
COUNTERWEIGHT
REMOVAL AND INSTALLATION
MONITOR PANEL
REMOVAL AND INSTALLATION
AUTO-DECELERATION・OLSS CONTROLLER
REMOVAL AND INSTALLATION

40 MAINTENANCE STANDARD
PTO
SWING CIRCLE
SWING MACHINERY
FINAL DRIVE
TRACK FRAME AND RECOIL SPRING
TRACK ROLLER
IDLER
CARRIER ROLLER
TRACK SHOE
CHARGING AND PTO LUBRICATION PUMP
L.H. 5-SPOOL CONTROL VALVE
R.H. 4-SPOOL CONTROL VALVE
SWING CONTROL VALVE
SWING MOTOR
CENTER SWIVEL JOINT
PILOT RELIEF VALVE
PPC VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT

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