Description

Komatsu PC650-5, PC650SE-5, PC650LC-5, PC710-5, PC710SE-5 1996 Service Manual

If you’re turning wrenches on a Komatsu PC650-5, PC650SE-5, PC650LC-5, PC710-5, or PC710SE-5 from the 1996 model year, you already know the gamble of guessing torque values or hoping the aftermarket wiring diagram is correct. That gamble costs shop time and parts. This is the OEM Service Manual – the same book Komatsu technicians used when these machines were new. 734 pages of factory-sourced data, not a third-party rehash. No shortcut fluff, no generic illustrations that sorta look like your machine. You get the real deal: Komatsu part numbers, factory tolerances, and the exact sequence for disassembly and reassembly. I’ve used these manuals since the late 90s, and they save me from having to redo jobs because some online forum had the wrong hydraulic pressure spec.

Every section here was written for mechanics who work with their hands. The valve clearance adjustment procedure (page 20-21, if you’re flipping) gives you the exact feeler gauge sizes and sequence for the SA6D140-1 engine. No “adjust until it feels right” nonsense. You get a number. Same for the track shoe tension – there’s a specific pressure range and a tool list. The manual’s layout mirrors what you’d do on the shop floor: test, adjust, disassemble, reassemble. No wasted pages.

3 Systems Covered That Keep the Machine Running

Section 10 covers structure and function with hydraulic circuit diagrams for the LH 5-spool control valve, RH 4-spool control valve, swing control valve, and the travel motor. If you’re chasing a drift issue or a weak swing, the hydraulic unit location map and the circuit diagram on page 10-1 let you trace lines without pulling the cab. The PTO lubrication system is explained separately – most aftermarket books skip that detail. Section 20 gives you the judgment tables for troubleshooting electrical and hydraulic systems. Need to isolate an E-2 fault (slow spee or lack of power)? The manual walks you through measuring pilot pressures and servo piston stroke. No guessing.

Valve Clearance: Do It Right the First Time

You’d think adjusting valve clearance is straightforward, but on the SA6D140-1, the sequence matters. The manual lists the firing order, the cold clearance spec in thousandths of an inch, and the order to rotate the crankshaft. There’s also a step for checking blow-by pressure – a diagnostic tool that tells you when rings or valves are on their way out before a full teardown. I keep this manual open on the bench whenever I’m doing a top-end job because one misadjusted valve on a Komatsu can cost you a bent pushrod. And no, the aftermarket book I once tried had the exhaust clearance off by 0.002″. That matters.

Does This Manual Cover the Fuel System and Electrical?

Yes. Section 20 includes testing and adjusting fuel injection timing, measuring intake air boost pressure (manifold pressure), and adjusting the fuel control linkage. The electrical circuit diagram is in section 10 – it’s a full schematic with connector positions and pin numbers for troubleshooting. The self-diagnostic display of the controllers is explained, so you can read fault codes without a dealer computer. If the machine won’t start or won’t stop, the E-12 and E-13 troubleshooting procedures list the exact relay and sensor checks. That’s the kind of depth that keeps a $300,000 machine from being a yard ornament.

Why OEM Beats Aftermarket for This Manual

Aftermarket manual publishers often take a 1992 PDF, slap a new cover on it, and call it a 1996 version. This manual is stamped by Komatsu, printed in Japan in 1996, and includes all revisions up to that date. The page numbers have revision marks (circles, arrows) so you know which pages were updated. The torque specs for control valve mounting bolts, final drive fasteners, and swing circle bolts come straight from the factory. When I see a stripped bolt hole on a travel motor, nine times out of ten it’s because someone used a generic torque chart. This manual saves you that headache. And if you need the engine-specific data, it cross-references to the 140 Series Engine Shop Manual. That’s how proper documentation works – it tells you where to find the rest of the story.

7 Major Test Procedures for Hydraulics

Section 20 has a table of judgment standard values for pressures, temperatures, and flow. You’ll find tools listed specifically for testing; e.g., the special adapter for measuring control circuit pressure. The manual gives you the safe procedure for releasing remaining pressure in the hydraulic circuit before you crack a line – something you skip at your own risk. It also covers checking locations that cause hydraulic drift of work equipment, which is a common complaint on high-hour machines. Every test references the corresponding component in section 10, so you can look up the internal seal kit numbers and disassembly steps.

This manual is 734 pages of factory knowledge. You can’t fake that depth. When you’re on a job site and the swing motor is acting up, having the OEM breakdown of the swivel joint, the PPC valve, and the safety lock valve makes the difference between a one-day fix and a three-day guess. I’ve been turning wrenches for 28 years, and I’ve never seen a third-party manual that matches Komatsu’s own documentation for accuracy.

What specific models are covered?

PC650-5, PC650SE-5, PC650LC-5, PC710-5, and PC710SE-5 starting from serial numbers: PC650-5 20001 and up, PC710-5 10001 and up.

How many pages and what year?

734 pages, published in 1996. It includes all revisions up to that date.

Does it include torque specs for hydraulic lines?

Yes. The testing and adjusting section lists torque values for control valve mounting bolts, final drive fasteners, and swing circle bolts. Exact foot-pounds are given for each fastener class.

Can I use this for the engine separately?

The manual covers the SA6D140-1 engine’s adjustments (valve clearance, injection timing, blow-by) but also references the separate 140 Series Engine Shop Manual for full engine rebuild details.

Related Manuals You Might Need

• Komatsu PC650-5 PC710-5 1996 Workshop Manual – 734 Pages OEM
• Demag Komatsu H 285 S Service Manual – 544 Pages of Factory Specs
• Komatsu WA430-6 Service Manual – 306-Page OEM Shop Manual

For background on how heavy equipment transmissions work, see Manual Transmission and Manual Transmission on Wikipedia.

Stop wasting billable hours on guesswork. Access the Factory Manual now and get the exact specs Komatsu put on paper for these machines.