PC2000-8 Shop Manual

SEN01607-02
HYDRAULIC
EXCAVATOR
PC2000 -8
SERIAL NUMBERS 20001 and up
SEN01609-02
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC2000-8
Machine model Serial number

PC2000-8 20001 and up
00 Index and foreword 1

Index
Composition of shop manual................................................................................................................ 2

Table of contents .................................................................................................................................. 4
PC2000-8 1
SEN01609-02 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN01607-02
00 Index and foreword SEN01608-02

Index SEN01609-02 q
Foreword and general information SEN01610-01
01 Specification SEN01611-00
Specification and technical data SEN01612-00
10 Structure, function and maintenance standard SEN01613-00

Engine and cooling system SEN01614-00
Power train SEN01615-00
Undercarriage and frame SEN01616-00
Hydraulic system, Part 1 SEN01618-00
Work equipment SEN01621-00
Cab and its attachments SEN01622-00
Electrical system SEN01623-00
20 Standard value table SEN01624-00

Standard service value table SEN02006-00 Q
30 Testing and adjusting SEN01625-00

Testing and adjusting, Part 1 SEN02007-00 Q
40 Troubleshooting SEN01626-00
Failure code table and fuse locations SEN02011-00 Q
General information on troubleshooting SEN02012-00 Q
Troubleshooting by failure code, Part 1 SEN02096-00 Q
2 PC2000-8

Troubleshooting of electrical system (E-mode) SEN02103-00 Q
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02104-00 Q
Troubleshooting of mechanical system (S-mode) SEN02105-00 Q
50 Disassembly and assembly SEN01627-00

General information on disassembly and assembly SEN02133-00
Engine and cooling system (12V140E-3) SEN02134-00
Engine (12V140E-3) SEN02135-00
Hydraulic system SEN02138-00
90 Diagrams and drawings SEN01628-01

Hydraulic diagrams and drawings SEN01629-00
Electrical diagrams and drawings SEN01630-01 q
PC2000-8 3
Table of contents 1
00 Index and foreword
Index SEN01609-02
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN01610-01

Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling electric equipment and hydraulic component ........................................................... 11
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN01612-00
Specification and technical data .................................................................................................. 2
Specification drawings ............................................................................................................. 2
Specifications........................................................................................................................... 4
Weight table ............................................................................................................................. 6
Table of fuel, coolant and lubricants ........................................................................................ 9
10 Structure, function and maintenance standard

Engine and cooling system SEN01614-00
Engine and cooling system ......................................................................................................... 2
Radiator and oil cooler............................................................................................................. 2
PTO ......................................................................................................................................... 4
PTO lubrication system............................................................................................................ 6
Power train .................................................................................................................................. 2
Power train............................................................................................................................... 2
Swing machinery ..................................................................................................................... 3
Swing circle.............................................................................................................................. 6
Final drive ................................................................................................................................ 8
Sprocket................................................................................................................................... 11
Undercarriage and frame ............................................................................................................ 2
Track frame.............................................................................................................................. 2
Idler.......................................................................................................................................... 4
Carrier roller............................................................................................................................. 6
Track roller ............................................................................................................................... 7
Track shoe ............................................................................................................................... 8
HIC system .............................................................................................................................. 13
4 PC2000-8

Hydraulic system, Part 1 ............................................................................................................. 4
Hydraulic piping drawing ......................................................................................................... 4
Hydraulic tank .......................................................................................................................... 6
Oil cooler ................................................................................................................................. 8
Line oil filter ............................................................................................................................. 10
Pilot oil filter ............................................................................................................................. 11
Return oil filter ......................................................................................................................... 12
Motor drain oil filter .................................................................................................................. 13
Pump drain filter ...................................................................................................................... 14
Accumulator............................................................................................................................. 15
Travel junction valve ................................................................................................................ 17
Solenoid valve ......................................................................................................................... 20
Hydraulic cylinder .................................................................................................................... 26
Greasing system...................................................................................................................... 28
Center swivel joint ................................................................................................................... 38
Control valve............................................................................................................................ 2
Electronic OLSS system .......................................................................................................... 30
Swing motor............................................................................................................................. 34
Cooling fan motor (For radiator and oil cooler) ........................................................................ 42
Cooling fan pump .................................................................................................................... 48
Travel motor............................................................................................................................. 2
Hydraulic pump........................................................................................................................ 14
PPC valve ................................................................................................................................ 32
Variable back pressure valve................................................................................................... 44
Suction selector valve.............................................................................................................. 48
PPC cut-off valve ..................................................................................................................... 52
Work equipment .......................................................................................................................... 2
Work equipment ...................................................................................................................... 2
Dimensions of work equipment ............................................................................................... 4
Cab and its attachments.............................................................................................................. 2
Air conditioner piping ............................................................................................................... 2
Cab .......................................................................................................................................... 3
Electrical system ......................................................................................................................... 2
Engine control.......................................................................................................................... 2
Electrical control system .......................................................................................................... 13
Monitor system ........................................................................................................................ 55
Sensor ..................................................................................................................................... 83
ORBCOMM terminal................................................................................................................ 95
PC2000-8 5
20 Standard value table

Standard service value table SEN02006-00
Standard service value table ....................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting................................. 2
Standard service value table for chassis ................................................................................. 3
30 Testing and adjusting

Testing and adjusting, Part 1 SEN02007-00
Testing and adjusting, Part 1 ....................................................................................................... 3
Tools for testing, adjusting, and troubleshooting...................................................................... 3
Measuring engine speed ......................................................................................................... 6
Testing air boost pressure........................................................................................................ 7
Testing exhaust temperature ................................................................................................... 8
Testing exhaust color ............................................................................................................... 9
Adjusting valve clearance ........................................................................................................ 11
Testing compression pressure ................................................................................................. 13
Testing blow-by pressure ......................................................................................................... 15
Testing engine oil pressure ...................................................................................................... 16
Handling fuel system parts ...................................................................................................... 17
Releasing residual pressure in fuel system ............................................................................. 17
Testing fuel pressure................................................................................................................ 18
Testing leakage from pressure limiter and return rate from injector......................................... 19
Bleeding air from fuel circuit .................................................................................................... 22
Bleeding air from fuel circuit (low-grade fuel specification)...................................................... 26
Testing fuel system for leakage ............................................................................................... 28
Testing and adjusting air conditioner compressor belt tension ................................................ 30
Testing swing circle bearing clearance .................................................................................... 3
Remaining pressure relief from HIC circuit .............................................................................. 4
Gas filling in HIC circuit accumulator ....................................................................................... 4
Bleeding air from HIC circuit and supplying oil to it ................................................................. 6
Testing and adjusting track shoe tension................................................................................. 8
Testing and adjusting work equipment, swing and travel circuit oil pressures......................... 11
Testing and adjusting control circuit oil pressure
(output pressure of self pressure reducing valve) ............................................................ 15
Testing and adjusting main pump control signal ...................................................................... 17
Measuring fan speed ............................................................................................................... 20
Measuring fan pump EPC solenoid current ............................................................................. 21
Measuring fan pump EPC solenoid valve output pressure ...................................................... 22
Oil pressure measuring points for pump discharge pressure or
jet sensor differential pressure ......................................................................................... 24
Measuring PPC valve output pressure .................................................................................... 25
Measuring solenoid valve outlet pressure ............................................................................... 30
Adjusting work equipment and swing PPC valve..................................................................... 32
Testing and adjusting travel deviation...................................................................................... 33
Testing work equipment hydraulic drift cause portion .............................................................. 35
Testing oil leakage ................................................................................................................... 36
Remaining pressure relief from hydraulic circuit...................................................................... 39
Air bleeding from each component .......................................................................................... 40
Air bleeding from PPC circuit................................................................................................... 45
Testing and adjusting auto grease system............................................................................... 47
Adjusting mirrors...................................................................................................................... 50
6 PC2000-8

Special functions of machine monitor ...................................................................................... 2
Handling controller voltage circuit............................................................................................ 57
VHMS controller initial setting procedure ................................................................................ 2
Precautions for replacing VHMS controller.............................................................................. 19
Preparation work for troubleshooting of electrical system ....................................................... 25
Pm-clinic service...................................................................................................................... 27
Measurement procedure ......................................................................................................... 28
40 Troubleshooting
Failure code table and fuse locations SEN02011-00
Failure code table and fuse locations.......................................................................................... 2
Failure code table .................................................................................................................... 2
Before carrying out troubleshooting of electrical system ......................................................... 9
General information on troubleshooting SEN02012-00
General information on troubleshooting ...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting ................................................................................... 3
Checks before troubleshooting ................................................................................................ 4
Classification and procedures of troubleshooting .................................................................... 5
Connection table for connector pin numbers ........................................................................... 9
T-adapter box and T-adapter table .......................................................................................... 42
Troubleshooting by failure code, Part 1 SEN02096-00
Troubleshooting by failure code, Part 1....................................................................................... 3
Failure code [0410KA] Fuel LV. Sensor Failure ....................................................................... 3
Failure code [0410KB] Fuel LV. Sensor Failure ....................................................................... 4
Failure code [6014NX] Hydraulic Oil Filter Clogging
(or change of VHMS-LED display from n5 to 51) ............................................................. 5
Failure code [8800ZG] Auto grease abnormally ...................................................................... 6
Failure code [7@HAZL] VR1/P1F Relief Press Abnormality ................................................... 7
Failure code [7@HBZL] VL1/P1R Relief Press Abnormality ................................................... 8
Failure code [7@HCZL] VR2/P2F Relief Press Abnormality ................................................... 9
Failure code [7@HDZL] VL2/P2R Relief Press Abnormality ................................................... 10
Failure code [AA10NX] Aircleaner Clogging............................................................................ 12
Failure code [AB00KE] Charge Voltage Low ........................................................................... 14
Failure code [aB00KE] Low Upper ALR Charge Voltage
Failure code [B@BAZG] Eng. Oil Press. Low ......................................................................... 18
Failure code [B@BAZK] Eng. Oil Level Low ........................................................................... 20
Failure code [B@BCNS] Eng. Water Overheat ....................................................................... 22
Failure code [B@BCZK] Eng. Water Lvl Low .......................................................................... 24
Failure code [B@CBNS] PTO Oil Overheat
Failure code [B@HANS] Hydr. Oil Overheat ........................................................................... 28
Failure code [B@HAZK] Low Hydraulic Oil Level
Failure code [CA111] ECM Critical Internal Failure ................................................................. 32
Failure code [CB111] ECM Critical Internal Failure ................................................................. 34
Failure code [CA115] Eng. Ne and Bkup Speed Sens Error ................................................... 36
Failure code [CB115] Eng. Ne and Bkup Speed Sens Error ................................................... 37
Failure code [CA122] Chg Air Press Sensor High Error .......................................................... 38
Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 40
Failure code [CA131] Throttle Sensor High Error .................................................................... 42
PC2000-8 7
Failure code [CA132] Throttle Sensor Low Error..................................................................... 44

Failure code [CA135] Eng Oil Press Sensor High Error .......................................................... 46
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................... 48
Failure code [CA144] Coolant Temp Sens High Error ............................................................. 50
Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 52
Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 54
Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 56
Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 58
Failure code [CB187] Sens Supply 2 Volt Low Error ............................................................... 58
Failure code [CA212] Eng Oil Temp Sensor High Error........................................................... 60
Failure code [CA213] Eng Oil Temp Sensor Low Error ........................................................... 62
Failure code [CA221] Ambient Press Sens High Error ............................................................ 4
Failure code [CA222] Ambient Press Sens Low Error............................................................. 6
Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 8
Failure code [CB227] Sens Supply 2 Volt High Error .............................................................. 10
Failure code [CA234] Eng Over Speed.................................................................................... 12
Failure code [CA238] Ne Speed Sens Supply Volt Error ......................................................... 14
Failure code [CB238] Ne Speed Sens Supply Volt Error ......................................................... 16
Failure code [CA263] Fuel Temp Sensor High Error ............................................................... 18
Failure code [CB263] Fuel Temp Sensor High Error ............................................................... 20
Failure code [CA265] Fuel Temp Sensor Low Error ................................................................ 21
Failure code [CB265] Fuel Temp Sensor Low Error ................................................................ 21
Failure code [CA271] IMV/PCV1 Short Error........................................................................... 22
Failure code [CB271] IMV/PCV1 Short Error........................................................................... 24
Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 26
Failure code [CB272] IMV/PCV1 Open Error .......................................................................... 28
Failure code [CA273] PCV2 Short Error .................................................................................. 30
Failure code [CB273] PCV2 Short Error .................................................................................. 32
Failure code [CA274] PCV2 Open Error.................................................................................. 34
Failure code [CB274] PCV2 Open Error.................................................................................. 36
Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................ 38
Failure code [CA342] Calibration Code Incompatibility ........................................................... 50
Failure code [CB342] Calibration Code Incompatibility ........................................................... 50
Failure code [CA351] Injectors Drive Circuit Error................................................................... 52
Failure code [CB351] Injectors Drive Circuit Error................................................................... 54
Failure code [CA352] Sens Supply 1 Volt Low Error ............................................................... 56
Failure code [CB352] Sens Supply 1 Volt Low Error ............................................................... 56
Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 58
Failure code [CB386] Sens Supply 1 Volt High Error .............................................................. 60
Failure code [CA441] Battery Voltage Low Error ..................................................................... 62
Failure code [CB441] Battery Voltage Low Error ..................................................................... 62
Failure code [CA442] Battery Voltage High Error .................................................................... 63
Failure code [CB442] Battery Voltage High Error .................................................................... 63
Failure code [CA449] Rail Press Very High Error .................................................................... 64
Failure code [CB449] Rail Press Very High Error .................................................................... 64
Failure code [CA451] Rail Press Sensor High Error................................................................ 4
Failure code [CB451] Rail Press Sensor High Error................................................................ 6
Failure code [CA452] Rail Press Sensor Low Error................................................................. 8
8 PC2000-8
Failure code [CB452] Rail Press Sensor Low Error ................................................................ 8

Failure code [CA553] Rail Press High Error ............................................................................ 9
Failure code [CB553] Rail Press High Error ............................................................................ 10
Failure code [CA554] Rail Press Sensor In Range Error ........................................................ 11
Failure code [CB554] Rail Press Sensor In Range Error ........................................................ 11
Failure code [CA559] Rail Press Low Error ............................................................................. 12
Failure code [CB559] Rail Press Low Error ............................................................................. 16
Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 20
Failure code [CB689] Eng Ne Speed Sensor Error ................................................................. 22
Failure code [CA691] Intake Air Temp Sens High Error .......................................................... 24
Failure code [CA692] Intake Air Temp Sens Low Error ........................................................... 26
Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 27
Failure code [CB731] Eng Bkup Speed Sens Phase Error...................................................... 27
Failure code [CA757] All Persistent Data Lost Error ............................................................... 28
Failure code [CB757] All Persistent Data Lost Error ............................................................... 28
Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 30
Failure code [CB778] Eng Bkup Speed Sensor Error.............................................................. 32
Failure code [CA781] CEN Communication Error ................................................................... 34
Failure code [CB781] CEN Communication Error ................................................................... 36
Failure code [CA1117] Persistent Data Lost Error ................................................................... 37
Failure code [CB1117] Persistent Data Lost Error ................................................................... 37
Failure code [CA1257] Harness Key Error .............................................................................. 38
Failure code [CB1257] Harness Key Error .............................................................................. 39
Failure code [CB1548] Inj #7(R#1) Open/Short Error.............................................................. 40
Failure code [CB1551] Inj #10(R#4) Open/Short Error............................................................ 44
Failure code [CB1552] Inj #11(R#5) Open/Short Error ............................................................ 46
Failure code [CB1553] Inj #12(R#6) Open/Short Error............................................................ 48
Failure code [CA1633] KOMNET Data link Time out Error...................................................... 52
Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 54
Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 56
Failure code [CA2249] Rail Press Very Low Error................................................................... 57
Failure code [CB2249] Rail Press Very Low Error................................................................... 57
Failure code [CA2555] Grid Heater Relay Volt Low Error ....................................................... 58
Failure code [CA2556] Grid Heater Relay Volt High Error....................................................... 60
Failure code [D110KB] Battery Relay Drive S/C...................................................................... 4
Failure code [D163KB] Flash Light Relay S/C......................................................................... 6
Failure code [D195KA] Step Light Relay Disc ......................................................................... 8
Failure code [D195KY] Step Light Relay S/C .......................................................................... 10
Failure code [D1E9KB] Wiper Drive Relay 1 S/C .................................................................... 12
Failure code [D1EAKB] Wiper Drive Relay 2 S/C.................................................................... 14
Failure code [D1EBKB] Lower Wiper Brake Relay Short Circuit ............................................. 16
Failure code [D1ECKB] Upper Wiper Brake Relay Short Circuit ............................................. 18
Failure code [DA22KK] Pump 1 Solenoid Power Low Error .................................................... 20
Failure code [dA22KK] Pump 2 Solenoid Power Low Error .................................................... 22
Failure code [DA25KP] Pump 1 Sens Supply Vol Low Error ................................................... 24
Failure code [dA25KP] Pump 2 Sens Supply Vol Low Error ................................................... 26
Failure code [DA26KP] 5V Sensor 2 Power Abnormality ........................................................ 28
Failure code [DA29KQ] Pump 1 Model Select Abnormality .................................................... 30
Failure code [dA29KQ] Pump 2 Model Select Abnormality ..................................................... 32
Failure code [DA2RMC] CAN Discon (Pump 1 Con Detected) ............................................... 34
Failure code [dA2RMC] CAN Discon (Pump 2 Con Detected) ................................................ 36
Failure code [DA2TMC] Pump Comm. ECM Child Abnormality .............................................. 38
Failure code [DBB0KK] VHMS Source Voltage Error
PC2000-8 9
Failure code [DBB0KQ] VHMS Connector Mismatch

(or change of VHMS-LED display from nF to 11) ............................................................. 42
Failure code [DBB5KP] VHMS 5V source sys Error
Failure code [DBBQKR] KOM-NET/c error
Failure code [DGE5KX] Ambient Air Temp Sensor Failure
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C .............................................................. 52
Failure code [DGT3KZ] PTO Temp Sensor Failure
Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure
Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure
Failure code [DGT5KB] Exhaust Temp. Sensor LBF Failure
Failure code [dGT5KB] Exhaust Temp. Sensor LBR Failure
Failure code [DGT6KA] Exhaust Temp. Sensor RBF Failure
Failure code [dGT6KA] Exhaust Temp. Sensor RBR Failure
Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure
Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure
Failure code [DH25KX] VR1/P1F J/S Dif Press Sensor Abnormality ...................................... 20
Failure code [DH26KX] VL1/P1R J/S Dif Press Sensor Abnormality ...................................... 22
Failure code [DH27KX] VR2/P2F J/S Dif Press Sensor Abnormality ...................................... 24
Failure code [DH28KX] VL2/P2R J/S Dif Press Sensor Abnormality ...................................... 26
Failure code [DHE5KB] Blowby Pres. Sensor Failure
Failure code [DHE5KY] Blowby Pres. Sensor Failure
Failure code [DHH2KA] Hydraulic oil filter Sensor Failure
Failure code [DHPEKX] VR1/P1F Pump P. Sensor Abnormality ............................................. 34
Failure code [DHPFKX] VL1/P1R Pump P. Sensor Abnormality ............................................. 36
Failure code [DHPGKX] VR2/P2F Pump P. Sensor Abnormality ............................................ 38
Failure code [DHPHKX] VL2/P2R Pump P. Sensor Abnormality ............................................. 40
Failure code [DHPSKX] Auto Grease Press Sensor Abnormality ........................................... 42
Failure code [DHPTKX] Fan(RAD) Pump P. Sensor Open Circuit........................................... 44
Failure code [DHPUKX] Fan(O/C) Pump P. Sensor Open Circuit ........................................... 46
Failure code [DHS3KX] Arm Dig PPC Press Sensor Abnormality........................................... 48
Failure code [DHS4KX] Bucket Curl PPC Press Sensor Abnormality ..................................... 50
Failure code [DHS8KX] Boom Raise PPC Press Sensor Abnormality .................................... 52
Failure code [DHS9KX] Boom Lower PPC Press Sensor Abnormality ................................... 54
Failure code [DHSAKX] Swing Right PPC Press Sensor Abnormality .................................... 56
Failure code [DHSBKX] Swing Left PPC Press Sensor Abnormality ...................................... 58
Failure code [DHSCKX] Arm Dump PPC Press Sensor Abnormality...................................... 60
Failure code [DHSDKX] Bucket Dump PPC Press Sensor Abnormality ................................. 62
10 PC2000-8

Failure code [DUM3KB] Auto Grease Caution LED Short Circuit ........................................... 3
Failure code [DUM4KB] FAN Reverse LED Short Circuit........................................................ 4
Failure code [DV20KB] Travel Alarm S/C ................................................................................ 5
Failure code [DW41KA] Swing Priority Sol Open Circuit ......................................................... 7
Failure code [DW41KB] Swing Priority Sol Short Circuit ......................................................... 9
Failure code [DW45KA] Swing Brake Sol. Disc....................................................................... 11
Failure code [DW45KB] Swing Brake Sol. S/C........................................................................ 14
Failure code [DW91KA] Straight-Travel Sol. Disc.................................................................... 16
Failure code [DW91KB] Straight-Travel Sol. S/C..................................................................... 18
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc. ...................................................... 20
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C ........................................................ 21
Failure code [DW7BKA] Fan Motor (RAD) Reverse Sol Open Circuit..................................... 22
Failure code [DW7BKB] Fan Reverse Sol. S/C ....................................................................... 24
Failure code [DW7HKA] Fan Motor(O/C) Reverse Sol Open Circuit....................................... 26
Failure code [DW7HKB] Fan Motor(O/C) Reverse Sol Short Circuit ....................................... 28
Failure code [DWA3KA] Arm throttle Valve/L Sol Open Circuit ............................................... 30
Failure code [DWA3KB] Arm throttle Valve/L Sol Short Circuit ............................................... 32
Failure code [DWA4KA] Arm throttle Valve/R Sol Open Circuit............................................... 34
Failure code [DWA4KB] Arm throttle Valve/R Sol Short Circuit ............................................... 36
Failure code [DWA5KA] Auto Grease Sol Open Circuit .......................................................... 38
Failure code [DWA5KB] Auto Grease Sol Short Circuit........................................................... 40
Failure code [DWA6KA] Boom throttle Valve Sol Open Circuit ............................................... 41
Failure code [DWA6KB] Boom throttle Valve Sol Short Circuit................................................ 43
Failure code [DWK0KA] 2-stage Relief Sol. Disc. ................................................................... 45
Failure code [DWK0KB] 2-stage Relief Sol. S/C ..................................................................... 47
Failure code [DWK2KA] Back Press Comp Valve Sol Open Circuit ........................................ 48
Failure code [DWK2KB] Back Press Comp Valve Sol Short Circuit ........................................ 49
Failure code [DWN5KA] Fan(RAD) Pump EPC Sol Open Circuit ........................................... 3
Failure code [DWN5KB] Fan(RAD) Pump EPC Sol Short Circuit ........................................... 5
Failure code [DWNCKA] Fan(O/C) Pump EPC Sol Open Circuit ............................................ 6
Failure code [DWNCKB] Fan(O/C) Pump EPC Sol Short Circuit ............................................ 7
Failure code [DXAAKA] P1F EPC Sol Disc ............................................................................. 8
Failure code [DXAAKB] P1F EPC Sol S/C .............................................................................. 10
Failure code [DXABKA] P1R Pump EPC Sol. Disc. ................................................................ 12
Failure code [DXABKB] P1R Pump EPC Sol. S/C .................................................................. 14
Failure code [DXACKA] P2F Pump EPC Sol. Disc. ................................................................ 16
Failure code [DXACKB] P2F Pump EPC Sol. S/C .................................................................. 18
Failure code [DXADKA] P2R Pump EPC Sol. Disc. ................................................................ 20
Failure code [DXADKB] P2R Pump EPC Sol. S/C .................................................................. 22
Failure code [DY2CKB] Washer Drive S/C .............................................................................. 24
Failure code [DY20MA] Low Wiper Working Abnormality ....................................................... 26
Failure code [DY2FMA] Upper Wiper Working Abnormality .................................................... 29
Failure code [F@BBZL] High Blowby Pressure
Failure code [F@BYNR] Very High LBF CYL Exhaust Temp
Failure code [f@BYNR] Very High LBR CYL Exhaust Temp
Failure code [F@BYNS] High LBF CYL Exhaust Temp
Failure code [f@BYNS] High LBR CYL Exhaust Temp
Failure code [F@BZNR] Very High RBF CYL Exhaust Temp
PC2000-8 11
Failure code [f@BZNR] Very High RBR CYL Exhaust Temp

Failure code [F@BZNS] High RBF CYL Exhaust Temp
Failure code [f@BZNS] High RBR CYL Exhaust Temp
Failure code [LA10ZL] RAD system fan pump relief pressure high error ................................ 50
Failure code [LA20ZL] O/C system pump relief pressure high error ....................................... 51
Troubleshooting of electrical system (E-mode) SEN02103-00
Troubleshooting of electrical system (E-mode) ........................................................................... 4
Contents of troubleshooting table ............................................................................................ 6
E-1 When starting switch is turned ON, machine monitor displays nothing ............................ 8
E-2 When starting switch turned ON (before starting engine), basic check item lights up ...... 10
E-3 Engine does not start (Engine does not turn).................................................................... 12
E-4 Auto-decelerator does not operate.................................................................................... 16
E-5 Automatic warm-up system does not operate................................................................... 17
E-6 Preheater does not work ................................................................................................... 18
E-7 Whole work equipment, swing operation and machine travel operation are disabled ...... 20
E-8 Machine push-up function does not work.......................................................................... 22
E-9 Boom shockless function cannot be released................................................................... 24
E-10 Machine monitor does not display some items ............................................................... 26
E-11 Contents of display by machine monitor are different from applicable machine ............. 27
E-12 Fuel level monitor lights up in red while engine is running .............................................. 28
E-13 Hydraulic oil temperature gauge does not indicate normally .......................................... 29
E-14 Fuel level gauge does not indicate normally ................................................................... 30
E-15 Swing lock monitor does not indicate normally ............................................................... 32
E-16 Machine monitor display anything even when operated on monitor switch section........ 34
E-17 Wiper does not work ....................................................................................................... 35
E-18 Monitoring function does not display "Travel" normally................................................... 42
E-19 Travel alarm does not sound........................................................................................... 44
E-20 All of room lamp, headlamp and working lamp do not light up........................................ 45
E-21 Air conditioner does not work.......................................................................................... 50
E-22 Step light does not light up or goes off ............................................................................ 52
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02104-00
Troubleshooting of hydraulic and mechanical system (H-mode)................................................. 3
Before troubleshooting for hydraulic and mechanical systems................................................ 3
Table of failure modes and causes .......................................................................................... 8
Information in troubleshooting table......................................................................................... 10
H-1 Speed or power of whole work equipment, travel, and swing is low ................................. 11
H-2 Engine speed lowers remarkably or engine stalls............................................................. 13
H-3 Work equipment, swing, and travel mechanism do not move........................................... 14
H-4 Abnormal noise comes from around hydraulic pump........................................................ 16
H-5 Speed or power of boom is low......................................................................................... 17
H-6 Speed or power of arm is low............................................................................................ 19
H-7 Speed or power of bucket is low ....................................................................................... 20
H-8 Boom does not move ........................................................................................................ 21
H-9 Arm does not move........................................................................................................... 21
H-10 Bucket does not move .................................................................................................... 21
H-11 Hydraulic drift of work equipment is large. ...................................................................... 22
H-12 Time lag of work equipment is large ............................................................................... 23
H-13 Heavy lift function does not work or is not reset. ............................................................ 24
H-14 Machine push-up function does not work or is not reset................................................. 24
H-15 Boom shockless function does not work or is not reset .................................................. 24
H-16 Machine gradually deviates during traveling................................................................... 26
H-17 Machine deviates excessively when started to travel ..................................................... 29
H-18 Machine deviates excessively during multiple operations .............................................. 30
H-19 Traveling speed or power is low...................................................................................... 30
12 PC2000-8
H-20 Travel system does not move (only one side) ................................................................ 31
H-21 Upper structure does not swing ...................................................................................... 32
H-22 Swing speed or acceleration is low................................................................................. 34
H-23 In compound operation of work equipment, swing speed or acceleration is low ............ 36
H-24 Upper structure overruns remarkably when it stops swinging ........................................ 37
H-25 Large shock is made when upper structure stops swinging ........................................... 38
H-26 Large abnormal sound comes from when upper structure stops swinging..................... 39
H-27 Hydraulic drift of work equipment is large in swing operation ......................................... 40
H-28 Fan rotation is abnormal (large noise or vibration of fans, or fan overheating) .............. 41
Troubleshooting of mechanical system (S-mode) SEN02105-00
Troubleshooting of mechanical system (S-mode) ....................................................................... 3
Method of using troubleshooting charts................................................................................... 3
S-1 Starting performance is poor ............................................................................................. 6
S-2 Engine does not start ........................................................................................................ 7
S-3 Engine does not pick up smoothly .................................................................................... 10
S-4 Engine stops during operations ........................................................................................ 11
S-5 Engine does not rotate smoothly ...................................................................................... 12
S-6 Engine lacks output (or lacks power) ................................................................................ 13
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 15
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 16
S-9 Oil becomes contaminated quickly ................................................................................... 17
S-10 Fuel consumption is excessive ....................................................................................... 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .............................. 19
S-12 Oil pressure drops........................................................................................................... 20
S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 21
S-14 Coolant temperature becomes too high (overheating).................................................... 22
S-15 Abnormal noise is made ................................................................................................. 23
S-16 Vibration is excessive ..................................................................................................... 24
50 Disassembly and assembly

General information on disassembly and assembly SEN02133-00
General information on disassembly and assembly.................................................................... 2
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tool list......................................................................................................................... 7
Sketches of special tools ......................................................................................................... 10
Engine and cooling system (12V140E-3) SEN02134-00
Engine and cooling system (12V140E-3).................................................................................... 2
Removal and installation of power container assembly........................................................... 2
Removal and installation of engine, PTO and hydraulic pump assembly ................................ 7
Removal and installation of radiator assembly ........................................................................ 18
Removal and installation of aftercooler assembly ................................................................... 19
Removal and installation of hydraulic oil cooler assembly ...................................................... 21
Removal and installation of fuel cooler assembly.................................................................... 22
Removal and installation of cooling assembly ......................................................................... 23
Removal and installation of fan motor assembly ..................................................................... 27
Removal and installation of fuel tank assembly....................................................................... 28
Engine (12V140E-3) SEN02135-00
Engine (12V140E-3).................................................................................................................... 2
Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of cylinder head assembly ............................................................... 5
Removal and installation of fuel injector .................................................................................. 18
Removal and installation of engine front seal .......................................................................... 28
Removal and installation of engine rear seal........................................................................... 31
PC2000-8 13

Power train .................................................................................................................................. 2
Removal and installation of PTO assembly ............................................................................. 2
Disassembly and assembly of PTO assembly......................................................................... 3
Removal and installation of swing motor and swing machinery assembly .............................. 7
Disassembly and assembly of swing machinery assembly ..................................................... 9
Removal and installation of swing circle assembly.................................................................. 19
Removal and installation of final drive assembly ..................................................................... 20
Disassembly and assembly of final drive assembly................................................................. 22
Undercarriage and frame ............................................................................................................ 2
Removal and installation of track shoe assembly.................................................................... 2
Removal and installation of idler assembly.............................................................................. 4
Disassembly and assembly of idler assembly ......................................................................... 5
Disassembly and assembly of idler adjust cylinder assembly ................................................. 7
Removal and installation of idler cushion cylinder assembly................................................... 8
Disassembly and assembly of idler cushion cylinder assembly .............................................. 9
Removal and installation of track roller assembly.................................................................... 10
Disassembly and assembly of track roller assembly ............................................................... 11
Removal and installation of carrier roller assembly ................................................................. 13
Disassembly and assembly of carrier roller assembly............................................................. 14
Removal and installation of revolving frame assembly ............................................................ 18
Removal and installation of counterweight assembly .............................................................. 21
Hydraulic system SEN02138-00
Hydraulic system ......................................................................................................................... 2
Removal and installation of hydraulic tank assembly .............................................................. 2
Removal and installation of hydraulic pump assembly ............................................................ 5
Removal and installation of hydraulic pump input shaft oil seal .............................................. 10
Removal and installation of control valve assembly ................................................................ 11
Disassembly and assembly of control valve assembly............................................................ 18
Removal and installation of center swivel joint assembly ........................................................ 22
Disassembly and assembly of center swivel joint assembly.................................................... 23
Removal and installation of swing motor assembly ................................................................. 24
Removal and installation of travel motor assembly ................................................................. 25
Disassembly and assembly of work equipment PPC valve assembly..................................... 26
Disassembly and assembly of travel PPC valve assembly ..................................................... 28
Disassembly and assembly of hydraulic cylinder assembly .................................................... 29
Work equipment .......................................................................................................................... 2
Removal and installation of bucket cylinder assembly ............................................................ 2
Removal and installation of bucket assembly .......................................................................... 4
Removal and installation of arm cylinder ................................................................................. 6
Removal and installation of arm assembly .............................................................................. 8
Removal and installation of boom cylinder assembly .............................................................. 10
Removal and installation of boom assembly ........................................................................... 12
Cab and its attachments.............................................................................................................. 2
Removal and installation of operator cab assembly ................................................................ 2
Removal and installation of operator cab glass (adhesion glass)............................................ 5
Removal and installation of operator cab (assembly-type)...................................................... 12
Removal and installation of cab base assembly...................................................................... 13
Electrical system ......................................................................................................................... 2
Removal and installation of air conditioner unit assembly ....................................................... 2
Removal and installation of monitor assembly ........................................................................ 6
Removal and installation of engine controller assembly.......................................................... 7
14 PC2000-8
Removal and installation of pump controller assembly ........................................................... 8

Removal and installation of VHMS controller assembly .......................................................... 9
Removal and installation of Orbcomm terminal assembly for VHMS ...................................... 9
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN01629-00
Hydraulic diagrams and drawings ............................................................................................... 3
Hydraulic circuit diagram ......................................................................................................... 3
Electrical diagrams and drawings SEN01630-01
Electrical diagrams and drawingss.............................................................................................. 3
Electrical circuit diagram (1/2) ................................................................................................. 3
Electrical circuit diagram (2/2) ................................................................................................. 5
Connector arrangement diagram............................................................................................. 7
PC2000-8 15
SEN01609-02
PC2000-8 Hydraulic excavator
Form No. SEN01609-02
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 12-06 (01)
16
SEN01610-01
PC2000-8

PC2000-8 20001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling electric equipment and hydraulic component .................................................................................11
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
PC2000-8 1
Safety notice 1 (Rev. 2006/09)

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
Wearing protective goggles
wear loose work clothes, or clothes with 7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc. Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 PC2000-8
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When larly careful to check that they are
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
PC2000-8 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 PC2000-8
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
PC2000-8 5
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refrigerant
gas (R134a).
k If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or adding
it, you must be qualified for handling
the refrigerant and put on protective
goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 PC2000-8
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.
PC2000-8 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 PC2000-8
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
PC2000-8 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 PC2000-8
Handling electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
PC2000-8 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 PC2000-8
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
PC2000-8 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 PC2000-8
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
PC2000-8 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the com-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 PC2000-8
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.
PC2000-8 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 PC2000-8
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
PC2000-8 19
Connectors newly used for Tier 3 engines

1. Slide lock type 2. Pull lock type (PACKARD-2)
(FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engine
q 107 – 170, 12V140 engines q Various temperature sensors
q Various pressure sensors and NE Example)
speed sensor Intake air temperature sensor in
Examples) intake manifold: TIM
Intake air pressure in intake manifold: Fuel temperature sensor: TFUEL
PIM (125, 170, 12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor: POIL Coolant temperature sensor: TWTR,
(125, 170, 12V140 engines) etc.
Oil pressure switch Disconnect the connector by pulling lock
(107, 114 engines) (B) (on the wiring harness side) of connec-
Ne speed sensor of flywheel housing: tor (2) outward.
NE (107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 PC2000-8
3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
PC2000-8 21
q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 PC2000-8
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
PC2000-8 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 PC2000-8
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
PC2000-8 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 PC2000-8
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.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
PC2000-8 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 PC2000-8
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC2000-8 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 PC2000-8
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
PC2000-8 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
32 PC2000-8
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
PC2000-8 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
No. of across Thread diame-
Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
34 PC2000-8
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
PC2000-8 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

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
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
36 PC2000-8
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
PC2000-8 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 PC2000-8
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC2000-8 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 PC2000-8
SEN01610-01

© 2006 KOMATSU
All Rights Reserved
42
SEN01612-00
PC2000-8

PC2000-8 20001 and up
01 Specification 1
Specification and technical data
Specification and technical data...................................................................................................................... 2
Specification drawings.......................................................................................................................... 2
Specifications ....................................................................................................................................... 4
Weight table ......................................................................................................................................... 6
Table of fuel, coolant and lubricants ..................................................................................................... 9
PC2000-8 1
SEN01612-00 01 Specification
Specification and technical data 1

Specification drawings 1
Backhoe specification 1
Item Unit PC2000-8

A Overall length mm 17,030
B Overall height mm 7,135
With slide ladder Without slide ladder
C Overall width mm
7,550 7,235
D Track shoe width mm 810
E Height of machine cab mm 5,970
F Height of operator’s cab mm 7,030
G Tail swing radius mm 5,980
H Track overall length mm 7,445
J Length of track on ground mm 5,780
K Min. ground clearance mm 825
2 PC2000-8
Working range drawing
Item Unit PC2000-8

A Max. digging height mm 13,410
B Max. dumping height mm 8,650
C Max. digging depth mm 9,235
D Max. vertical wall depth mm 2,710
E Max. reach at ground level mm 15,305
F Max. digging reach mm 15,780
Min. swing radius of
G mm 7,500
work equipment
PC2000-8 3
Specifications 1
Backhoe specification
Machine model PC2000-8

Serial number 20001 and up
Bucket capacity m 3
12.0
Weight of machine kg 200,000
Max. digging depth mm 9,235
Working range
Max. vertical wall depth mm 2,710

Max. digging reach mm 15,780
Max. reach at ground level mm 15,305
Max. digging height mm 13,410
Performance
Max. dumping height mm 8,650

Max. digging force kN {kg} 697 {71,100}
Swing speed rpm 4.8
Swing max. slope angle deg. 9.0
Travel speed km/h 2.7
Gradeability deg. 33
Ground pressure (standard shoe) kPa {kg/cm }2
190 {1.94}
With work equipment mm 17,030
Overall height Overall length
Upper structure only mm 8,500

Lower crawler only
mm 7,440
(equipped with standard shoe)
With work equipment mm 7,135
Upper structure only mm 5,170

Lower crawler only
mm 2,840
With slide ladder Without slide ladder
Overall width
Dimensions
With work equipment mm

7,550 7,235
Upper structure only mm
Lower crawler only
mm 5,650 (with step)
Overall width of crawler mm 5,410
Ground clearance of upper structure mm 2,095
Min. ground clearance mm 825
Tail swing radius mm 5,980
Min. swing radius of work equipment mm 7,500
Height of work equipment at min. swing radius mm 11,880
Length of track on ground mm 5,780
Track gauge mm 4,600
Height of machine cab mm 5,970
Standard shoe width mm 810
4 PC2000-8

Model SAA12V140E-3
4-cycle, water-cooled, V type,
Type direct injection, with turbocharger and
aftercooler (air cooled)
No. of cylinders – bore × stroke mm 12 – 140 × 165
Piston displacement l {cc} 30.48 {30,480}
Flywheel horsepower kW/rpm {HP/rpm} 728/1,800 {976/1,800}
Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 4,510/1,350 {460/1,350}

High idle rpm 1,980 ± 50
Low idle rpm 825 ± 25
Min. fuel consumption g/kWh {g/HPh} 207 {154}
Starting motor 24 V, 11 kW × 2
Alternator 24 V, 50 A × 2
Battery 12 V, 170 Ah × 4
Radiator fan type Aluminum wave 4-row
Carrier roller 3 on each side
carriage
Under-
Track roller 8 on each side

Assembly-type double grouser,
Track shoe
49 on each side
Type Main pump: variable displacement tan-
dem piston type 2 (HPV375 + 375)
Fan pump: variable displacement tandem
piston type 1 (HPV95 + 95)
Hydraulic
PTO lubrication pump: gear type 1

Delivery
pump
(SBL (1) 21)

Main pump P1: 629 + 629, P2: 518 + 518
l/min Fan pump: 160 + 160
PTO lubrication pump: 35
Main pump: 29.6 {300},
Set pressure MPa {kg/cm2}
Fan pump: 24.5 {250}
Type × No. 5-spool + 5-spool type × 2
Hydraulic Control
valve
Hydraulic system
Control method Hydraulic type

Piston type (with brake valve, shaft brake):
Travel motor
2 (KMF340)
motor
Piston type (with safety valve, shaft brake):

Swing motor
2 (KMF230)
Boom Arm Bucket
Hydraulic cylinder
Cylinder type Double-acting piston

Inside diameter of cylinder mm 300 250 200
Outside diameter of piston rod mm 200 160 140
Stroke mm 2,647 2,134 2,170
Max. distance between pins mm 6,480 5,267 5,420
Min. distance between pins mm 3,833 3,133 3,250
Hydraulic tank Box-shaped, with breather
Hydraulic filter Pump outlet, tank return side
Hydraulic cooler Air cooled
PC2000-8 5
Weight table 1
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Power container assembly 16,238
q Engine body 3,375
q Engine mount bracket, engine oil drain 364
q Air cleaner, muffler, tail pipe 488
q PTO 1,092
q PTO lubrication piping, PTO drain 30
q Radiator, radiator drain 1,249
q Oil cooler 1,124
q Fuel piping 55
q Harness 58
q Main pump (F) 490
q Second pump (R) 490
q Fan pump 220
q Delivery line 212
q Oil cooler line 57
q Pump drain line, pump drain filter 83
q PPC delivery line, pilot filter 27
q Air conditioner compressor, air conditioner piping,
40
heater piping
q Engine hood, cooling duct,
3,789
power container exterior
q Power container base frame 2,668
q Power container partition 142
q Underguard 185
Operator’s cab assembly 4,135
q Harness 50
q VHMS controller, pump controller,
ORBCOMM controller, PHMS controller, 20
power distribution
q Horn 5
q PPC return line, safety lock, accumulator 42
q Junction joint 17
q PPC travel control line 3
q PPC work equipment control line, boom shockless 14
q Operator’s seat 50
q Sub seat 11
q Seat belt 1
q Operator’s cab body, wiper, left rearview mirror 1,540
q Floor mat 16
q Air conditioner 95
q Fire extinguisher 4
q First aid box 5
6 PC2000-8
Unit: kg
q Cab mount (viscous mount) 108
q Work equipment PPC valve (LH and RH),
130
control stand (LH and RH), left gauge panel
q Travel PPC valve, travel lever, travel pedal 22
q Cab base, cab round step,
2,002
emergency refuge ladder
Left deck (with battery) with power assist ladder 2,097
without power assist ladder 1,674
Right deck (incl. counterweight handrail) 1,085
Fuel tank 2,112
Fuel piping 26
Harness 40
Travel alarm 3
Grease piping, injector 62
Hydraulic tank, return oil filter, oil level sensor 1,884
Main valve, valve bracket 1,732
Suction line 290
Delivery line, in-line filter 128
Oil cooler line 127
Return line (excl. return filter) 111
PPC drain line 34
Boom line 195
Arm line 171
Bucket line 93
Travel line 91
Straight travel line 11
Swing line 49
Solenoid valve 22
Solenoid valve line 8
Shuttle valve line 51
PPC control line 8
PPC main line 38
PPC delivery line 26
Revolving frame 19,355
Boom foot pin, boom cylinder bottom pin 475
Air conditioner piping, heater piping,
70
electronic controller, receiver dryer
Cab rear floor, revolving frame front step,
511
center maintenance floor, drum can cover
Right rearview mirror 6
Counterweight 24,000
Swing machinery 2,136
Swing motor 210
Swivel joint 290
Pump, drum can bracket, oil piping, grease reel line 309
PC2000-8 7
Unit: kg
Track frame assembly 68,051
q Swing circle 3,633
q Travel piping 139
q Idler cushion oil pressure part 332
q Travel final drive 6,514
q Idler 2,462
q Idler cushion cylinder part 946
q Track roller 5,586
q Carrier roller 762
q Track Standard triple shoe (810 mm) 17,020
Wide triple shoe (1,010 mm) 21,040
q Center frame, grease bus 13,562
q Crawler frame 14,331
q Center cover (if equipped) 646
q Travel motor cover 515
q Travel motor guard 937
q Track frame step 81
q Track roller guard Single type 1,231
Divided welding type
2,328
(if equipped)
Boom 18,389
Hose between machine and boom foot 118
Arm cylinder hose 74
Boom cylinder 4,790
Boom cylinder hose 73
Arm cylinder 2,470
Arm 8,699
Hose between boom and arm 97
Bucket cylinder 1,752
Link 2,030
Bucket Bucket body (incl. tooth, shroud) 9,737
Wear kit (if equipped) 2,508
8 PC2000-8
Table of fuel, coolant and lubricants 1

a For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
Unit: l
Swing
Engine oil Final drive Hydraulic Cooling
PTO case machinery Fuel tank Grease
pan case system system
case
(Each of (Each of
Specified capacity (l) 128 36 front and right and 2400 3400 180 200
rear) 30 left) 85
(Each of (Each of
Refill capacity (l) 120 36 front and right and 1300 — — 200
rear) 30 left) 85
PC2000-8 9
SEN01612-00
© 2006 KOMATSU
All Rights Reserved
10
SEN01614-00
PC2000-8

PC2000-8 20001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine and cooling system ............................................................................................................................. 2
Radiator and oil cooler ......................................................................................................................... 2
PTO ...................................................................................................................................................... 4
PTO lubrication system ........................................................................................................................ 6
PC2000-8 1
SEN01614-00 10 Structure, function and maintenance standard
Engine and cooling system

Radiator and oil cooler 1
2 PC2000-8
1. Reservoir tank
2. Aftercooler outlet tube
3. Aftercooler inlet tube
4. Radiator inlet hose
5. Radiator
6. Radiator bypass tube
7. Fan pump
8. Aftercooler
9. Fan drive motor (radiator side)
10. Fan guard
11. Fan (radiator side)
12. Engine return hose
Specifications
1. Fan
(Radiator side)
Outside diameter:1,450 mm
No. of vanes: 6
Rotating speed: Variable
(Standard. spec.: Max. 840 rpm)
(+55°C spec: Max. 1,100 rpm)
2. Radiator
Core type: Aluminum wave 4-row, 3.5/2P
Fin pitch: 3.5 mm
Releasing pressure for pressure valve:
0.05 MPa {0.5 kg/cm2}
Releasing pressure for vacuum valve:
–0.005 MPa {–0.05 kg/cm2}
3. Aftercooler
Core type: Aluminum wave 4.0/2P
Fin pitch: 4.0 mm
PC2000-8 3
PTO
4 PC2000-8
1. Drive gear (No. of teeth: 57)

2. Coupling
3. Main shaft
4. Connection plate
5. PTO case
6. Driven gear (No. of teeth: 72, 60)
7. Driven gear (No. of teeth: 56)
8. Breather
A. Center of No. 1 pump (HPV375 + 375) shaft

B. Center of No. 2 pump (HPV375 + 375) shaft
C. Center of fan pump (HPV95 + 95) shaft
D. Center of input shaft
Specifications
Lubricating oil : 36 l
Reduction ratio : Input shaft: 1.0
No. 1 pump (HPV375 + 375): 60/57 = 1.053
No. 2 pump (HPV375 + 375): 72/57 = 1.263
Fan pump (HPV95 + 95): 56/57 = 0.982
Unit: mm
No. Check Item Criteria Remedy
Backlash between main shaft Standard size Repair limit Replace
9
and drive gear coupling 0.09 – 0.26 —
Backlash between driven gear
10 0.14 – 0.29 —
and hydraulic pump Adjust
Backlash between driven gear
11 0.14 – 0.29 —
and fan pump shaft
PC2000-8 5
PTO lubrication system
1. PTO case Hydraulic circuit diagram

2. PTO oil reservoir
3. Gear pump (SAL(1)020)
4. PTO oil filter
Outline
The lubricating oil sucked by gear pump (3) from
PTO oil reservoir (2) passes through PTO oil filter
(4) to PTO case (1), is divided in PTO case to lubri-
cate and cool the gears.
6 PC2000-8
SEN01614-00
© 2006 KOMATSU
All Rights Reserved
8
SEN01615-00
PC2000-8

PC2000-8 20001 and up

Power train
Power train...................................................................................................................................................... 2
Power train ........................................................................................................................................... 2
Swing machinery.................................................................................................................................. 4
Swing circle .......................................................................................................................................... 6
Final drive............................................................................................................................................. 8
Sprocket ............................................................................................................................................. 10
PC2000-8 1
Power train
Power train
2 PC2000-8
1. Idler
2. Center swivel joint
3. Swing motor (KMF230)
4. 5-spool control valve (L1)
5. 5-spool control valve (L2)
6. 5-spool control valve (R1)
7. 5-spool control valve (R2)
8. Final drive, sprocket
9. Travel motor (KMF340)
10. Engine (SAA12V140E)
11. PTO
12. P1 pump (HPV375+375)
13. P2 pump (HPV375+375)
14. PF pump (HPV95+95+SAL (1) 020)
15. Swing brake solenoid valve
16. Swing machinery
17. Swing circle
PC2000-8 3
Swing machinery
4 PC2000-8
1. Swing pinion (No. of teeth: 16)

2. Cover
3. Case
4. Coupling
5. No. 2 planetary gear (No. of teeth: 32)
6. No. 2 ring gear (No. of teeth: 83)
9. Cover
10. Dipstick
11. Swing motor
12. No. 1 sun gear (No. of teeth: 35)
13. No. 1 planetary carrier
16. Drain plug
Specification
Reduction ratio: (35 + 190)/35 × (17 + 83)/17 = 37.815
Unit: mm
Backlash between swing motor Standard clearance Clearance limit
17
shaft and No. 1 sun gear 0.177 – 0.282 —
Backlash between No. 1 sun
18 0.14 – 0.39 —
gear and No. 1 planetary gear
Backlash between No. 1
19 0.20 – 0.57 —
planetary gear and ring gear
20 planetary carrier and No. 2 sun 0.41 – 0.72 —
gear
Backlash between No. 2 sun Replace
21 0.15 – 0.38 —
Backlash between No. 2 plane-
22 0.23 – 0.67 —
tary gear and ring gear
23 0.06 – 0.24 —
planetary gear and coupling
Backlash between coupling and
24 0.09 – 0.25 —
swing pinion
Backlash between swing pinion
25 0.18 – 1.58 —
and swing circle
Clearance between plate and
26 0.50 – 1.00 —
coupling
Clearance between No. 1 sun Repair hard
27 2.22 – 4.68 — chrome plating
gear and ring
or replace
Wear of swing pinion oil seal Standard size Repair limit
28
contact surface –0
180 –0.115 —
PC2000-8 5
Swing circle
1. Swing circle inner race (No. of teeth: 131) a. Inner race soft zone “S” position
2. Swing circle outer race (Upper side) b. Outer race soft zone “S” position
3. Roller
4. Swing circle outer race (Lower side)
Unit: mm
Clearance of bearing in axial Standard clearance Clearance limit
5 direction (when mounted on Replace
machine) 0.5 – 1.5 2.0
Specifications
Reduction ratio: 131/16 = 8.1875
Amount of grease: 80 l (G2-LI)
6 PC2000-8
Final drive
1. No. 2 planetary carrier Specifications

2. No. 2 ring gear (No. of teeth: 69) Reduction ratio:
3. Housing –67/12 × (13 + 80)/31 × (15 + 69)/15 = –223.677
4. Floating seal Amount of final drive oil: 85 l (each) (TO30)
5. Sprocket
6. Hub
7. Housing
10. Drive gear (No. of teeth: 12)
11. Travel motor case
12. Travel motor
13. No.1 sun gear (No. of teeth 13)
14. Driven gear (No. of teeth: 67)
15. Case
8 PC2000-8
Unit: mm
Backlash between drive gear Standard clearance Clearance limit
19
and driven gear 0.21 – 0.73 —
20 0.085 – 0.207 —
gear and driven gear
21 0.25 – 0.46 —
22 0.089 – 0.293 —
gear and No. 2 planetary carrier Replace
Backlash between No. 2 plane-
23 0.24 – 0.62 —
tary gear and No. 2 sun gear
24 Backlash of housing 0.067 – 0.258 —
Backlash between housing and
25 0.276 – 0.808 —
No. 2 ring gear
Clearance between housing
26 10 —
and hub
Standard shim thickness of
27 2 Adjust
cover mounting part
PC2000-8 9
Sprocket
Unit: mm
Standard size Repair limit
1 Wear of tooth tip
482.7 470.7 Build-up
2 Thickness of tooth root 40 34 welding or
3 Width of tooth 140 130 replace
4 Wear of tooth shape Repair limit: 6 (measure with sprocket tooth shape)
10 PC2000-8
a The above drawing is reduced to 41%. Enlarge it to 244% to return it to the full scale and make a copy
on an OHP sheet.
PC2000-8 11
SEN01615-00
© 2006 KOMATSU
All Rights Reserved
12
SEN01616-00
PC2000-8

PC2000-8 20001 and up

Undercarriage and frame
Undercarriage and frame ................................................................................................................................ 2
Track frame .......................................................................................................................................... 2
Idler ...................................................................................................................................................... 4
Carrier roller ......................................................................................................................................... 6
Track roller ........................................................................................................................................... 7
Track shoe............................................................................................................................................ 8
HIC system......................................................................................................................................... 13
PC2000-8 1
Undercarriage and frame 1

Track frame 1
1. Idler 6. Track roller

2. Track frame 7. Track shoe
3. Carrier roller 8. Idler cushion
4. Center frame 9. Roller guard
5. Final drive 10. Accumulator
Unit: mm
Standard size Tolerance Repair limit
Track Rebuild
Top-to-bottom width 253 ±2 233
11 frame
of idler guide
Idler
250 ± 0.5 215 Replace
support
Track
420 ±2 430 Rebuild
Left-to-right width of frame
12
idler guide Idler +1.0
416 408 Replace
support +0
2 PC2000-8
Specification
810 mm shoe 1,010 mm shoe
Item
Width of shoe 810 mm 1,010 mm
Type Double grouser Triple grouser
Link pitch 317.5 mm 317.5 mm
Number of shoes 49 49
PC2000-8 3
Idler 1
4 PC2000-8
Unit: mm
No. Check item Criteria Remedy
Outside diameter of Standard size Repair limit
1
protruding part 1,072 —
Outside diameter of tread
2 1,030 1,018 Rebuild or
surface
replace
3 Thickness of tread — —
4 Height of tread 21 27
5 Overall width 311 —
6 Width of tread 85 —
Standard Tolerance Standard Clearance
Clearance between shaft and size Shaft Hole clearance limit
7
bushing –0.060 +0.37
165 0.29 – 0.49 —
–0.120 –0.23
Replace
Standard Tolerance Standard Interfer- bushing
Interference between idler size Shaft Hole interference ence limit
8
and bushing +0.134 –0.123 0.209 –
175 —
+0.086 –0.175 0.309
Standard clearance Clearance limit
9 Play of axial direction
0.65 – 1.07 —
PC2000-8 5
Carrier roller 1
Unit: mm
1 Outside diameter of flange
275 —
2 Outside diameter of tread 240 220 Rebuild or
3 Width of tread 85 — replace
4 Thickness of tread 47 37
5 Width of flange 25 —
size Shaft Hole clearance limit
Clearance between –0.060 +0.360 0.280 –
6 Outside 95 —
shaft and bushing –0.120 +0.220 0.480
–0.060 +0.390 0.205 –
Inside 125
–0.150 +0.145 0.540
Standard Tolerance Standard Interference Replace
size Shaft Hole interference limit bushing
Interference between +0.087 +0.035 0.022 –
7 Outside 102.5 —
roller and bushing +0.057 +0.035 0.087
+0.180 +0.053 0.027 –
Inside 135
+0.080 –0.010 0.190
Play of roller in axial Standard clearance Clearance limit
8
direction 0.40 – 0.76 —
6 PC2000-8
Track roller 1
Unit: mm
1 Outside diameter of flange
400 —
Outside diameter of tread
2 340 328
surface Rebuild or
3 Thickness of tread 92.5 86.5 replace
4 Overall width 394 —
5 Width of tread 85 —
6 Width of flange 41.5 —
Clearance between shaft and size Shaft Hole clearance limit
7
bushing –0.060 +0.482 0.421 –
145 —
–0.120 +0.361 0.602 Replace
Standard Tolerance Standard Interference bushing
Interference between roller and size Shaft Hole interference limit
8
bushing +0.115 +0.025 0.042 –
155 —
+0.067 –0.015 0.130
Standard clearance Clearance limit
9 Play of axial direction Replace
0.29 – 0.68 —
PC2000-8 7
Track shoe 1
a P portion shows the link of bushing press fitting end.
8 PC2000-8
Unit: mm
1 Link pitch
317.8 320.8
Reverse or
When turned
Standard size replace
2 Bushing outside diameter Normal load Heavy load
116 — 111
Standard size Repair limit Adjust or
3 Thickness of bushing metal
22.5 17.5 replace
Rebuild or
4 Link height 195 182
replace
Thickness of link metal
5 49.5 36.5
(bushing press-fitting portion)
6 274 Replace
7 Shoe bolt pitch 96
8 33
Inside
9 148
width
Overall Repair or
10 Link 83
width replace
Tread
11 78
width
12 Protrusion of pin 2.9
13 Protrusion of regular bushing 10.75
Adjust or
14 Overall length of pin 353
replace
15 Overall length of bushing 247.4
16 Thickness of spacer —
17 Bushing 235 – 647 kN {24 – 66 ton}
Regular
18 470 – 1176 kN {48 – 120 ton}
Press-fitting force pin —
Master
*19 235 – 686 kN {24 – 70 ton}
pin
*Dry type track link
PC2000-8 9
Unit: mm
Tightening torque Additional tightening
a. Regular (Nm {kgm}) angle (deg.)
link 686.5 ± 68.6
120 ± 10
20 Shoe bolt {70 ± 7} Retighten
Tightening torque Additional tightening Lower limit torque
b. Master (Nm {kgm}) angle (deg.) (Nm {kgm})
link
— — —
Tolerance Standard
Standard size
Interference between bushing Shaft Hole interference
21
and link +0.652 +0.087
113 0.435 – 0.652
+0.522 +0.087
Interference between regular +0.496 –0.126
22 70 0.522 – 0.696
pin and link +0.396 –0.200
Tolerance Standard
Standard size
Clearance between regular pin Shaft Hole clearance
23
and bushing +0.496 +1.236 Adjust or
70 0.240 – 0.840
+0.396 +0.736 replace
Tolerance Standard
Standard size
Interference between master Shaft Hole interference
*24
pin and link +0.216 –0.126
70 0.302 – 0.416
+0.176 –0.200
Tolerance Standard
Standard size
Clearance between master pin Shaft Hole clearance
*25
and bushing +0.050 +1.436
69.8 0.886 – 1.486
–0.050 +0.936
*Dry type track link
10 PC2000-8
Double shoe
Unit: mm
1 Height of shoe
108 87
2 Height of grouser 23 2
Rebuild or
3 Thickness 8
replace
4 50
5 Length at tip 44
6 —
PC2000-8 11
Triple grouser shoe
Unit: mm
1 Height of shoe
127 109
2 Height of grouser 20 2
Rebuild or
3 Thickness 8
replace
4 44
5 Length at tip 35
6 35
12 PC2000-8
HIC system 1
1. Idler
2. Yoke
3. Plunger A
4. Plunger B
5. Cylinder
6. Stop valve
7. Relief-check valve
8. Accumulator
9. Check valve
10. Stop valve
11. Pressure reducing valve
12. Check valve
13. Right travel motor
15. Control valve (R.H.)
16. Line oil filter
17. Hydraulic pump (front)
Operation
q The space between yoke (2) and plunger (3) is q If idler (1) returns forward, the oil is returned by
filled with grease. The space between plunger (4) the gas pressure in the accumulator through
and cylinder (5) is filled with hydraulic oil at the the check valve of the relief-check valve to cyl-
constant pressure of 17.7 MPa {180 kg/cm2}. inder (5). The cushion force decreases and the
This hydraulic oil is connected through relief- system returns to the original condition accord-
check valve (7) to accumulator (8). ing to the forward movement of the idler.
q If idler (1) is moved back by external force,
plunger (4) is pressed and the pressure in cyl-
inder (5) increases. If this pressure increases
above the set pressure, relief-check valve (7)
opens and the oil flows into accumulator (8).
q The volume of the nitrogen gas in the accumula-
tor is reduced by the quantity of the oil pushed by
plunger (4). Since the gas pressure increases as
a result, the cushion force increases according to
movement of plunger (4).
PC2000-8 13
Accumulator (HIC system)
1. Valve
2. Body
3. Bladder
4. Check valve
Specification
Capacity: 32, 500 cc
Actuation pressure: 29.4 MPa {300 kg/cm2}
14 PC2000-8
SEN01616-00
© 2006 KOMATSU
All Rights Reserved
16
SEN01618-00
PC2000-8

PC2000-8 20001 and up

Hydraulic system, Part 1
Hydraulic system, Part 1 ................................................................................................................................. 4
Hydraulic piping drawing ...................................................................................................................... 4
Hydraulic tank ...................................................................................................................................... 6
Oil cooler .............................................................................................................................................. 8
Line oil filter ........................................................................................................................................ 10
Pilot oil filter.........................................................................................................................................11
Return oil filter .................................................................................................................................... 12
Motor drain oil filter............................................................................................................................. 13
Pump drain filter ................................................................................................................................. 14
Accumulator ....................................................................................................................................... 15
Travel junction valve........................................................................................................................... 17
Solenoid valve.................................................................................................................................... 20
Hydraulic cylinder............................................................................................................................... 26
PC2000-8 1
Greasing system ................................................................................................................................ 28

Center swivel joint .............................................................................................................................. 38
2 PC2000-8
Hydraulic system, Part 1 1

Hydraulic piping drawing 1
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Line oil filter
5. L1 control valve (5-spool)
6. L2 control valve (5-spool)
7. R1 control valve (5-spool)
8. R2 control valve (5-spool)
9. No. 1 pump (HPV375 + 375)
10. No. 2 pump (HPV375 + 375)
11. Fan pump (HPV95 + 95 + SAL (1) 020)
12. Swing motor
14. Travel motor
15. Oil cooler
16. Pump drain filter
17. Pilot oil filter
18. 8-spool solenoid valve assembly
18A. Back pressure compensation valve
selector solenoid valve
18B. Swing priority solenoid valve (right)
18C. 2-stage main relief solenoid valve
18D. Arm throttle solenoid valve (L1)
18E. Arm throttle solenoid valve (R2)
18F. Boom throttle solenoid valve (R1)
18G. Straight-travel valve
18H. Machine push-up solenoid valve
19. Swing holding brake solenoid valve
20. Bucket high cancel solenoid valve
21. Motor drain oil filter
22. Pilot selector valve (L1)
23. Pilot selector valve (R1)
24. Pilot selector valve (R2)
25. PPC cut-off valve
26. Travel shuttle valve
27. Travel junction valve
28. Variable back pressure compensation valve
29. Hydraulic tank
30. Return oil filter
31. Fan motor (Oil cooler)
32. Fan motor (Radiator)
33. Grease pump
34. HIC cylinder
35. Lock valve
36. PPC accumulator
37. Boom damper valve
38. Work equipment PPC valve (LH)
39. Work equipment PPC valve (RH)
40. Travel PPC valve
41. Accumulator (for oil cooler pressure)
4 PC2000-8
PC2000-8 5
Hydraulic tank 1
6 PC2000-8
1. Suction strainer proximity switch

2. Breather
3. Hydraulic tank
4. Suction strainer
5. Oil filler cap
6. Strainer
7. Hydraulic oil level sensor
8. Hydraulic oil temperature sensor
9. Hydraulic oil low temperature sensor
Specifications
Tank capacity: 1,910 l
Quantity of oil in tank: 1,215 l
Breather
Relief cracking pressure:
0.07 ± 0.01 MPa {0.7 ± 0.1 kg/cm2}
Suction cracking pressure:
Max. 0.002 MPa {0.02 kg/cm2}
Adjustment method for suction strainer proximity switch
PC2000-8 7
Oil cooler 1
8 PC2000-8
1. Fuel cooler
2. Oil cooler
3. Fan pump
4. Drain filter
5. Hydraulic motor for fan drive (oil cooler side)
6. Fan guard
7. Fan (oil cooler side)
Specifications
1. Fan
(Oil cooler side)
Outside diameter:1,450 mm
No. of vanes: 6
Rotating speed: Variable
(Standard. spec.: Max. 760 rpm)
(+55°C spec: Max. 1,100 rpm)
2. Oil cooler
Core type: PF 4-6, 3.0P
Fin pitch: 3.0 mm
3. Fuel cooler
Core type: CF 40-1, 4.5/2P
Fin pitch: 4.5 mm
PC2000-8 9
Line oil filter 1
1. Element Outline
2. Case There are 4 line oil filters installed to the discharge
3. Cover side of the hydraulic pump. They protect the circuit
and equipment by removing all dirt and dust from
A: From hydraulic pump the oil.
B: To control valve
10 PC2000-8
Pilot oil filter 1
1. Bracket
2. Cartridge
3. Safety valve
PC2000-8 11
Return oil filter 1
1. Cover Outline
2. Spring q There are 3 return oil filters installed to the side
3. Bypass valve face of the hydraulic tank. They remove the dirt
4. Bypass valve spring and dust in the return oil.
5. Element q Bypass valve set pressure:
6. Housing 0.15 ± 0.03 MPa {1.5 ± 0.3 kg/cm2}
A: From control valve

B: To hydraulic tank
12 PC2000-8
Motor drain oil filter 1
1. Bracket Outline
2. Safety valve q This filter is installed between the swing motor,
3. Cartridge travel motor, and hydraulic tank. It acts to
4. Element remove the dirt and foreign matter in the oil
coming from the drain port of each motor.
q Safety valve set pressure: 0.1 MPa {1.0 kg/cm2}
PC2000-8 13
Pump drain filter 1
1. Head Outline
2. Relief valve q The pump drain filter is installed between the
3. Cartridge hydraulic pump, fan pump and hydraulic tank.
4. Element It removes dirt and foreign matter from the oil
flowing in from each pump drain port.
q Safety valve set pressure:
147 ± 29 kPa {1.5 ± 0.3 kg/cm2}
14 PC2000-8
Accumulator 1
PPC accumulator
1. Cap Specifications
2. Nut Gas capacity: 5,100 cc
3. Cap Gas pressure: 1.18 MPa {12 kg/cm2}
4. Body
5. Bladder
6. Port
7. Nut
PC2000-8 15
Accumulator (for oil cooler pressure)
1. Accumulator System diagram

2. Oil cooler
3. Hydraulic tank
4. Control valve
5. Cooler check valve
6. Variable back pressure valve
7. Return filter
Outline
The accumulator is installed in the oil cooler
hydraulic circuit to cut the peak hydraulic pressure
of the oil cooler and secure the durability and reli-
ability.
1. Body
2. Bladder
3. Poppet
4. Film
5. Holder
6. Port
7. Plug
Specifications
Volume of gas: 500 cm3
Charge pressure: 0.098 MPa {1 kg/cm2}
16 PC2000-8
Travel junction valve 1
1. Valve body Specifications

2. Spool Spool change pressure:
3. Retainer 0.2 ± 0.05 MPa {2 ± 0.5 kg/cm2}
4. Spring
Outline
q The travel junction valve is used for the travel
circuit.
q When the machine travels straight, the travel
junction valve connects the travel circuits to
prevent travel deviation caused by the differ-
ence between the oil flow rates in the right and
left motors.
PC2000-8 17
System diagram
1. Travel PPC valve a. LH travel reverse

2. Control valve b. LH travel forward
3. Shuttle valve c. RH travel reverse
4. Travel junction valve d. RH travel forward
5. Swivel joint
6. RH travel motor
7. LH travel motor
18 PC2000-8
Solenoid valve 1
1. For back pressure compensation, 2-stage main relief, arm throttle, swing priority, straight travel, and
machine push-up
20 PC2000-8
1. Back pressure compensation valve solenoid valve Operation

2. Swing priority switching valve solenoid valve When solenoid is de-energized
3. 2-stage main relief solenoid valve q Since the signal current does not flow from the
4. Arm throttle valve (L1) solenoid valve controller to solenoid, coil (11) is de-energized.
5. Arm throttle valve (L2) solenoid valve For this reason, spool (12) is pushed to the left
6. Boom throttle valve (R1) solenoid valve by spring (14).
7. Straight travel solenoid valve q By this operation, the pass from port (P) to port
8. Machine push-up solenoid valve (A) is closed and the pressurized oil from the
9. Connector main pump does not flow into the actuator.
10. Movable core q At this time, the oil from the actuator is drained
11. Coil through ports (A) and (T) into the tank.
12. Spool
13. Block
14. Spring
A1: To back pressure compensation valve

A2: To PPC cutoff valve (CV2)
A3: To main relief valve
A4: To pilot valve (PV1)
A7: To PPC cutoff valves (CV1), (CV2)
A8: To main valves (L1), (R1)
P1: From pump
T: To hydraulic tank
ACC: Plug
When solenoid is energized
q The signal current flows from the controller to
solenoid, and coil (11) is energized. Accord-
ingly, spool (12) is pressed against to the right
side.
q By this operation, the pressurized oil from the
main pump flows through port (P) and spool (4)
to port (A), then flows into the actuator.
q At the same time, port (T) closes and stops the
oil from flowing to the tank.
PC2000-8 21
2. For swing holding brake and lock valve
22 PC2000-8
1. Swing holding brake solenoid valve

2. Connector
3. Coil
4. Movable core
5. Body
6. Plug
7. Spring
8. Spool
9. Body
10. Plug
11. Spring
12. Spool
T: To tank
A: To front and rear swing motors
(for swing holding brake)
To PPC valve (for safety lock)
P: From control pump
Operation
When solenoid is de-energized
q While the signal current is not flowing in from
the controller, coil (3) is de-energized. Accord-
ingly, spool (12) is pushed up by spring (11)
and spool (8) is pushed to the left by spring (7).
q Since port (P) is closed at this time, the oil from
the control pump does not flow to the actuator.
q The oil from the actuator flows through ports
(A) and (T) to the tank.
When solenoid is energized

q If the signal current flows in from the controller
and coil (3) is energized, spool (12) is pushed
down.
q Accordingly, the oil from the control pump flows
through port (P) to port (A) and spool (8) is
pushed to the right.
q If spool (8) is pushed to the right, the oil from
the control pump flows through ports (P) and
(A) to the actuator.
q Since port (T) is closed at this time, the oil
does not flow to the tank.
PC2000-8 23
3. For bucket high cancel
1. Connector When solenoid is energized

2. Movable core q If the signal current flows in from the controller,
3. Solenoid solenoid (3) is energized and movable core (2)
4. Spool is pushed to the right. Accordingly, spool (4) is
5. Body pushed to the right.
6. Spring q If spool (4) is pushed to the right, port (P) is
7. Plug closed and the oil from the PPC valve does not
flow to the control valve.
Operation q Since port (A) and port (T) are connected at
When solenoid is de-energized this time, the oil from the control valve flows to
q While the signal current is not flowing in from the tank.
the controller, solenoid (3) is de-energized and
spool (4) is set in the neutral position by spring
(6).
q At this time, port (P) and port (A) are con-
nected and the oil from the PPC valve flows to
the control valve.
24 PC2000-8
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
Bucket cylinder
26 PC2000-8
Unit: mm
Name of Standard Tolerance Standard Clearance
cylinder size Shaft Hole clearance limit
–0.050 +0.257 0.089 –
Boom 200 —
Clearance between –0.122 +0.039 0.379 Replace
1
piston rod and bushing –0.043 +0.228 0.089 – bushing
Arm 160 —
–0.105 +0.046 0.334
–0.043 +0.035 0.048 –
Bucket 140 —
–0.106 +0.005 0.141
–0.043 +0.025 0.043 –
Boom 180 1.0
Clearance between –0.106 +0.025 0.131
piston rod –0.043 +0.025 0.043 –
2 Arm 140 1.0
support shaft and –0.106 +0.025 0.131
bushing –0.043 +0.245 0.188 –
Bucket 140 1.0
–0.106 +0.145 0.351 Replace pin,
–0.043 +0.025 0.043 – bushing
Boom 180 1.0
Clearance between –0.106 +0.025 0.131
cylinder bottom –0.043 +0.025 0.043 –
3 Arm 140 1.0
support shaft and –0.106 +0.025 0.131
bushing –0.036 +0.457 0.406 –
Bucket 120 1.0
–0.090 +0.370 0.547
PC2000-8 27
Greasing system 1
28 PC2000-8
PC2000-8 29
Injector distribution valve line

Grease point Delivery

1 Front link + Bucket pin 1.30 cc/rev × 2
2 Front link + wrist pin 1.30 cc/rev × 4
3 Arm B boss 1.30 cc/rev × 4
4 Arm A boss + Bucket pin 1.30 cc/rev × 4
Arm 1.30 cc/rev × 2
5 Arm C boss + Bucket top pin
Boom 0.72 cc/rev × 2
6 Bucket cylinder bottom pin 0.97 cc/rev × 2
7 Arm cylinder head pin 1.30 cc/rev × 2
8 Boom foot pin 0.97 cc/rev × 4
9 Boom cylinder head pin 1.30 cc/rev × 2
10 Arm cylinder bottom pin 1.30 cc/rev × 2
11 Boom cylinder bottom pin 0.13 cc/rev × 2
12 Swing circle 1.30 cc/rev × 10
30 PC2000-8
Outline
q Auto grease function
If the grease mode selector switch is in the
auto grease position, the controller operates
the grease pump at constant time intervals and
the icon of the grease pump operating at the
set pressure is displayed on the monitor.
q Manual grease function
If the grease mode selector switch is in the
manual grease position, the controller oper-
ates the grease pump continuously.
q Grease level warning function
If the grease level lowers, the low-level switch
signal is inputted to the controller and warning
is displayed on the monitor and the grease
warning lamp blinks.
q Auto grease intervals
Auto grease interval Time from stop of pump to start
SMR 100 hours or less 5 minutes
Above SMR 100 hours 10 minutes
PC2000-8 31
Components
Grease pump
1. Vent valve Outline

2. Pump q In the auto grease system, this hydraulic pump
3. Follower plate supplies the grease from grease chamber (B).
4. Tube q This pump is double-action type, that is, it dis-
5. Cover charges grease in both upward and downward
6. Grease tank strokes.
7. Pressure gauge q This pump is operated automatically by the oil
pressure switch and controller.
A. Oil inlet port a When the grease is supplied, if pressure gauge
B. Grease chamber (7) indicates 4.9 – 19.6 MPa {50 – 200 kg/cm2},
C. Grease feed port the operation is normal.
(if equipped: with refill function) a If the pressure gauge indicates below 4.9 MPa
D. Grease drain port {50 kg/cm2}, grease tank is empty.
(if equipped: with refill function) a If the grease tank or vent valve is broken, the
T. Pump drain port caution lamp lights up and the contents of the
trouble are displayed on the machine monitor.
Grease delivery (Max.): 28 l/min

Set pressure (reducing valve):
2.3 ± 1.0 MPa {23.5 ± 1 kg/cm2}
Grease tank capacity: Approx. 180 kg
32 PC2000-8
Auto grease indicator Grease gun

q If the grease mode selector switch is set in q Use the grease gun to grease the parts which
“AUTO”, “AUTO” indicator (1) is displayed on are not greased by the auto grease system
the normal screen of the monitor. (trunnion at the front of the engine and tracks)
and the local parts which are greased by the
auto grease system.
Manual grease indicator

q If the grease mode selector switch is set in
“MANUAL”, “MANUAL” indicator (2) is dis-
played on the normal screen of the monitor.
PC2000-8 33
Hose reel
q The hose reel is used to store the grease gun
hose. It is the auto winder type.
34 PC2000-8
Injector distribution valve
1. Adjustment screw
2. Injector body
3. Injector piston
4. Piston spring
5. Slide valve
6. Manifold
Delivery: 0.13 – 1.31 cc/rev
PC2000-8 35
Operation
q Stage 1 q Stage 2
The grease pressurized by the pump pushes The grease flowing through passage (P)
up slide valve (5) and connects manifold (6) pushes down injection piston (3) and dis-
and passage (P). charges the grease in discharge chamber (D)
to oil hole (h).
36 PC2000-8
q Stage 3 q Stage 4
Injector piston (3) lowers to slide valve (5) and If slide valve (5) is pushed down, passage (P)
then pushes it down to disconnect manifold (6) is connected to discharge chamber (D) by
and passage (P). valve port (q) and the grease in measuring
chamber (M) is sent to discharge chamber (D)
for the next supply. The operation cycle is com-
pleted at this point.
PC2000-8 37
Center swivel joint 1
1. Cover B2 : To R.H. travel motor port PB

2. Body C1 : From L.H. travel control valve port A5
3. Slipper seal C2 : To L.H. travel motor port PB
4. Oil seal D1 : From L.H. travel control valve port B5
5. Shaft D2 : To L.H. travel motor port PA
P1 : To hydraulic tank
A1 : From R.H. travel control valve port A5 P2 : From L.H. and R.H. travel motor port T
A2 : To R.H. travel motor port PA T1 : To hydraulic tank
B1 : From R.H. travel control valve port B5 T2 : From L.H. and R.H. travel motor port T
Unit: mm
Clearance between rotor and Standard size Standard clearance Clearance limit
6 Replace
shaft 110 0.056 – 0.105 0.111
38 PC2000-8
SEN01618-00
© 2006 KOMATSU
All Rights Reserved
40
SEN01619-00
PC2000-8

PC2000-8 20001 and up

Control valve ........................................................................................................................................ 2
Electronic OLSS system .................................................................................................................... 30
Swing motor ....................................................................................................................................... 34
Cooling fan motor (For radiator and oil cooler) .................................................................................. 42
Cooling fan pump ............................................................................................................................... 48
PC2000-8 1

Control valve 1
L.H. 10-spool valve
2 PC2000-8
A1 : To arm cylinder head

A2 : To boom cylinder head
A3 : To bucket cylinder head
A4 : –
A5 : To L.H. travel motor [Port (PB)]
B1 : To arm cylinder bottom
B2 : To boom cylinder bottom
B3 : To bucket cylinder bottom
B4 : –
B5 : To L.H. travel motor [Port (PA)]
CN-P27: To controller
NCA1 : Pressure pick-up port (Jet sensor upstream pressure)
NCB1 : Pressure pick-up port (Jet sensor downstream pressure)
P1 : From P1 rear pump
P2 : From P2 rear pump
PA11 : From PPC valve (Arm IN)
PA21 : From PPC valve (Boom RAISE)
PA31 : From PPC valve (Bucket CURL)
PA41 : –
PA51 : From PPC valve (L.H. travel reverse)
PB11 : From PPC valve (Arm OUT)
PB21 : From PPC valve (Boom LOWER)
PB31 : From PPC valve (Bucket DUMP)
PB41 : –
PB51 : From PPC valve (L.H. travel forward)
PA42 : –
PA52 : From PPC valve (L.H. travel reverse)
PB22 : Drain
PB42 : –
PB52 : From PPC valve (L.H. travel forward)
PC1 : From boom priority selector valve
PP1 : From solenoid valve (Main relief valve)
PS1 : From solenoid valve (Machine push-up)
T : To tank (Main drain)
TC1 : Drain
TS : To swing motor [Port (S)]
1. L1 valve
2. L2 valve
PC2000-8 3
Sectional view
4 PC2000-8
L1 valve
PC2000-8 5
Sectional view
6 PC2000-8

A21: To boom cylinder head
A31: To bucket cylinder head
A41: –
A51: To L.H. travel motor [Port (PB)]
B21: To boom cylinder bottom
B31: To bucket cylinder bottom
B41: –
B51: To L.H. travel motor [Port (PA)]
1. Main relief valve

2. Spool (Arm Lo)
3. Spool (Boom Lo)
4. Spool (Bucket Hi)
5. –
6. Spool (L.H. travel Hi)
7. Valve body
8. Jet sensor and orifice
9. Jet sensor and relief valve
10. Jet sensor and differential pressure sensor
11. Orifice check valve
12. Check valve
13. Piston
14. Check valve
15. Check valve
Unit: mm
Free length
Installed Installed Installed
× outside Free length
16 Spool return spring length load load
diameter
431 N 345 N
69.9 × 57 63 —
{44 kg} {35.2 kg}
If damaged or
541 N 433 N
17 Spool return spring 74.5 × 38.1 71.5 — deformed,
{55.2 kg} {44.2 kg}
replace spring
18.8 N 15.1 N
18 Check valve spring 65.28 × 14 46 —
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
19 Check valve spring 78.2 × 26.6 52 —
{1.92 kg} {1.54 kg}
12.7 N 10.2 N
20 Check valve spring 20.8 × 12.2 13.5 —
{1.3 kg} {1.04 kg}
PC2000-8 7
8 PC2000-8
1. Arm Lo valve
2. Boom Lo valve
3. Bucket Hi valve
4. –
5. L.H. travel Hi valve
6. Safety-suction valve
7. 2-stage safety-suction valve
8. Suction valve
PC2000-8 9
L2 valve
10 PC2000-8
Sectional view
PC2000-8 11
A12: To arm cylinder head

A42: –
A52: To L.H. travel motor [Port (PB)]
B12: To arm cylinder bottom
B42: –
B52: To L.H. travel motor [Port (PA)]

2. Spool (Arm Hi)
3. Spool (Boom Hi)
4. Spool (Bucket Lo)
5. Spool (–)
6. Spool (L.H. travel Lo)
7. Valve body
11. Check valve
12. Check valve
Unit: mm
Free length
diameter
431 N 345 N
69.9 × 57 63 — If damaged or
{44 kg} {35.2 kg}
deformed,
541 N 433 N replace spring
14 Spool return spring 74.5 × 38.1 71.5 —
{55.2 kg} {44.2 kg}
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
12.7 N 10.2 N
{1.3 kg} {1.04 kg}
12 PC2000-8
14 PC2000-8
1. Arm Hi valve
2. Boom Hi valve
3. Bucket Lo valve
4. –
5. L.H. travel Lo valve
7. Suction valve
PC2000-8 15
R.H. 10-spool valve
16 PC2000-8

A2 : To boom cylinder head
A3 : To bucket cylinder head
A4 : To swing motor [Port (MB)]
A5 : To R.H. travel motor [Port (PA)]
B2 : To boom cylinder bottom
B3 : To bucket cylinder bottom
B4 : To swing motor [Port (MA)]
B5 : To R.H. travel motor [Port (PB)]
P1 : From P1 front pump
P2 : From P2 front pump
PA41 : From PPC valve (Right swing)
PA51 : From PPC valve (R.H. travel reverse)
PB21 : Drain
PB41 : From PPC valve (Left swing)
PB51 : From PPC valve (R.H. travel forward)
PA42 : –
PA52 : From PPC valve (R.H. travel reverse)
PB22 : From PPC valve (Boom LOWER)
PB42 : –
PB52 : From PPC valve (R.H. travel forward)
PC1 : From swing priority selector valve
PC2 : From boom priority selector valve
PS2 : From solenoid valve (Machine push-up)
T : To tank (Main drain)
TC1 : Drain
TC2 : Drain
TS : To swing motor [Port (S)]
1. R1 valve
2. R2 valve
PC2000-8 17
Sectional view
18 PC2000-8
R1 valve
PC2000-8 19
Sectional view
20 PC2000-8

A41: To swing motor [Port (MB)]
A51: To R.H. travel motor [Port (PA)]
B41: To swing motor [Port (MA)]
B51: To R.H. travel motor [Port (PB)]

2. Spool (Arm Lo)
3. Spool (Boom Hi)
4. Spool (Bucket Lo)
5. Spool (Swing)
6. Spool (R.H. travel Hi)
7. Valve body
12. Check valve
13. Piston
14. Check valve
15. Check valve
Unit: mm
Free length
diameter
431 N 345 N
69.9 × 57 63 —
{44 kg} {35.2 kg}
If damaged or
541 N 433 N
{55.2 kg} {44.2 kg}
replace spring
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
12.7 N 10.2 N
{1.3 kg} {1.04 kg}
PC2000-8 21
22 PC2000-8
1. Arm Lo valve
2. Boom Hi valve
3. Bucket Lo valve
4. Swing valve
5. R.H. travel Hi valve
7. Suction valve
PC2000-8 23
R2 valve
24 PC2000-8
Sectional view
PC2000-8 25
A12: To arm cylinder head

A42: To swing motor [Port (MB)]
A52: To R.H. travel motor [Port (PA)]
B12: To arm cylinder bottom
B42: To swing motor [Port (MA)]
B52: To R.H. travel motor [Port (PB)]

2. Spool (Arm Hi)
3. Spool (Boom Lo)
4. Spool (Bucket Hi)
5. –
6. Spool (R.H. travel Lo)
7. Valve body
12. Check valve
13. Piston
14. Check valve
15. Check valve
Unit: mm
Free length
diameter
431 N 345 N
69.9 × 57 63 —
{44 kg} {35.2 kg}
If damaged or
541 N 433 N
{55.2 kg} {44.2 kg}
replace spring
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
12.7 N 10.2 N
{1.3 kg} {1.04 kg}
26 PC2000-8
28 PC2000-8
1. Arm Hi valve
2. Boom Lo valve
3. Bucket Hi valve
4. –
5. R.H. travel Lo valve
7. 2-stage safety-suction valve
8. Suction valve
PC2000-8 29
Electronic OLSS system 1
30 PC2000-8
Function
q The electronic OLSS system converts signals
from the jet sensor to electronic signals by use
of the differential pressure sensor to enable
EPC valve to directly control the swash plate of
the variable displacement pump.
q Conventional OLSS used to control the flow
rate by conducting the signal pressures from
TVC valve, CO valve and NC valve to the
pump servo piston.
q The electronic OLSS system controls TVC, CO
and NC digitally. And sensing the lever signals,
jet sensor signals, pump discharge pressure
and engine speed, this system controls the
flow rate to ensure more efficient use of the q Output voltage (E) from the differential pres-
engine horsepower than available from the sure sensor is conducted to the controller.
hydraulic control. q Current (IEPC) being conducted from the con-
q As the spool stroke of the control valve troller to EPC valve increases output voltage
increases, carry-over flow rate (QC) (PI) of EPC. As the result, pump delivery (Q)
decreases, decreasing the differential pressure increases.
(PT – PD) output from the jet sensor. q The figure shows the relationship between the
control valve spool stroke and pump delivery (Q).
q Pump delivery (Q) increases roughly in propor-
tion to increase in the control valve spool
stroke.
Features
q Favorable fuel consumption results in the fine
control mode because the pump delivers the only
necessary flow rate, the reducing power loss.
q Favorable fuel consumption also results when
the lever is set to the neutral position since the
flow rate is kept at minimum and, thus, the
power loss is reduced.
q Startability of the pump increases significantly
q Voltage is output as output differential pressure since the pump driving torque at startup is small.
(PT – PD) is conducted to the differential pres- q Small spool stroke of the control valve enhances
sure sensor. the fine steering control since it decreases the
q The figure shows the relation between the pump delivery.
input and output signals, indicating that q This system saves power loss since it allows
decrease in output differential pressure (PT – setting a different speed on individual work
PD) results in increasing output voltage (E). equipment basis.
q Adding the digitized modulation enhances the
operability.
PC2000-8 31
Arm and boom throttle valves
Function Operating condition table

q When the sections with a high operating pres- Operating condition
sure and a low operating pressure are oper- No. Section
(*: throttling side)
ated simultaneously in the compound
Arm IN* + Boom RAISE
operation, the throttle valve brings balance to Arm throttle
Arm IN* + Bucket DUMP
the flow rate to respective work equipment by 1 valve
Arm IN* + Bucket CURL
preventing the operating pressure from flowing (L1 valve)
Arm OUT* + Boom RAISE
more to the low-pressure side.
Arm throttle
Arm IN* + Boom RAISE
2 valve
Arm OUT* + Boom Raise
(R2 valve)
Boom throttle
3 valve Swing + Boom RAISE*
(R1 valve)
32 PC2000-8
Operation
q As the output pressure to respective PPC valves
is generated according to a combination listed in
the operating condition table, the solenoid valve
outputs the pilot pressure responding to the sig-
nal from the controller and, as the result, the
selector valve is switched.
When the signal from the controller is present

q The selector valve is switched by the pilot
pressure from the solenoid valve and the pump
pressure is introduced at the result.
q Piston (4) is pushed down due to the area dif-
ference between (φd1) and (φd2).
q Stroke of orifice check valve (1) is disabled by
piston (4).
q The pressurized oil from the pump flows
through orifice (a) of orifice check valve (1),
retracting spring (3) and pushing up check
valve (2) in the process. Then it flows through
orifice (b) to the cylinder port.
q Flow of the pressurized oil to the cylinder port
is restricted by orifices (a) and (b).
When the signal from the controller is absent

q Port (PC) is drained. Thus, piston (4) does not
operate.
q As long as piston (4) remains inactive, the
pressurized oil from the pump flows to the cyl-
inder port by retracting spring (3) and pushing
up orifice check valve (1) and check valve (2).
q In this case, flow of the pressurized oil to the
cylinder port is not restricted.
PC2000-8 33
Swing motor 1
Type: KMF230AB-5
B : From swing holding brake solenoid valve Specifications

MA : From control valve Type : KMF230AB-5
MB : From control valve Theoretical displacement : 229.4 cm3/rev
S : From control valve Safety valve set pressure : 27.9 MPa {290 kg/cm2}
T : To tank Rated speed : 1,315 rpm
Brake release pressure : 1.9 MPa {19 kg/cm2}
1. Plate
2. Safety valve
34 PC2000-8
36 PC2000-8
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10. Cylinder block
11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Shuttle valve
Unit: mm
Free length
16 Check valve spring length load load If damaged or
diameter
deformed,
6.96 N 5.59 N replace spring
66.5 × 25.6 45.0 —
{0.71 kg} {0.57 kg}
7.45 N 5.98 N
17 Shuttle valve spring 24.5 × 11.6 14.5 —
{0.76 kg} {0.61 kg}
PC2000-8 37
Swing holding brake
1. When solenoid valve is de-energized 2. When solenoid valve is energized
Operation Operation
q As the swing holding brake is de-energized, q As the swing brake solenoid valve is ener-
the pressurized oil from the self pressure gized, the valve is switched.
reducing valve is shut off. q The pressurized oil from the self pressure
q Port (B) is connected to tank circuit (T). reducing valve is conducted brake chamber (a)
q Brake piston (7) is pushed down by brake through port (B).
spring (1). q After entering chamber (a), the pressurized oil
q Disc (5) and plate (6) are pushed together, and compresses brake spring (1) and pushes
the brake is applied. brake piston (7) up.
q Disc (5) is separated from plate (6), releasing
the brake.
38 PC2000-8
Relief valve
Outline
q The relief valve consists of check valves (2)
and (3), shuttle valves (4) and (5), and relief
valve (1).
Function
q When the machine is in the swing holding
mode, control valve (6) closes the motor outlet
circuit, but the motor rotation is continued by
inertial force.
q The motor output, therefore, is abnormally
increased, resulting in damaging the motor.
q In order to prevent the motor damages, the
relief valve relieves the abnormally high pres-
sure to port (S) from the motor outlet side
(high-pressure side) of the motor.
Operation
1. When starting swing
q When the swing control lever is operated to the
right-swing, the pressurized oil from the pump is
supplied to port (MA) through control valve (6).
q The pressure on port (MA) rises, the starting
torque is generated in the motor, and the motor
starts to rotate.
q The pressurized oil from the outlet port of the
motor passes from port (MB) through control
valve (6) and returns to the tank.
PC2000-8 39
2. When swing is stopped

q When the swing control lever is returned to
neutral, the supply of pressurized oil from the
pump to port (MA) is stopped.
q The pressurized oil from the motor outlet can't
return to the tank since the returning circuit to
the tank is closed from control valve (6). Thus,
pressure on port (MB) increases.
q Rotation resistance is generated on the motor
and hence the brake starts working.
q The pressure on port (MB) pushes shuttle
valve (4) as it goes higher than that on port
(MA).
q The pressure on chamber (C) is increased to
the s et pres su re of re lie f v alv e (1) a nd
becomes the same as that of port (MB).
q A high braking torque works on the motor,
thereby stopping the motor.
q When relief valve (1) is being actuated, the
relieved pressurized oil and the pressurized oil
from port (S) are fed to port (MA) through
check valve (3).
q Above prevents cavitation on port (MA).
40 PC2000-8
Cooling fan motor

(For radiator and oil cooler) 1
Type: LMF110
P : From fan pump

T : From cooler to tank
TC : To tank
Specifications
Type: LMF110
Capacity: 110.7 cm3/rev
Rated speed: 1,050 rpm
Rated flow rate: 116.2 l/min
Check valve clacking pressure: 78.5 kPa {0.8 kg/cm2}
Safety valve cracking pressure: 24.5 MPa {250 kg/cm2}
42 PC2000-8
1. Output shaft 8. End cover

2. Case 9. Center spring
3. Thrust plate 10. Suction valve
4. Shoe 11. Pilot valve
5. Piston 12. Reversible valve spool
6. Cylinder block 13. Safety valve
7. Valve plate
Unit: mm
Free length
14 Spool return spring length load load If damaged or
diameter
deformed,
146 N 117 N replace spring
62.66 × 19.8 53.5 —
{14.9 kg} {11.9 kg}
13.7 N 11.0 N
15 Suction valve spring 16.4 × 8.9 11.5 —
{1.4 kg} {1.12 kg}
PC2000-8 43
1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The hydraulic oil conducted to one side of cyl-
inder block (5) pushes respective pistons (4) to
generate force (F1) [F1 = P × xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a°) to
output shaft (1), the force is divided into com-
ponents (F2) and (F3).
q The radial component (F3) generates torque
[T = F3 × ri] against the (Y–Y) line connect-
ing the top dead center and bottom dead
center.
q The combined force of all torque [T = Σ (F3 × ri)]
rotates cylinder block (5) through the piston.
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
44 PC2000-8
2. Suction valve
Function 2) When the pump is stopped

q If the fan pump stops, the pressurized oil does q If the engine is stopped and the input revolu-
not flow into the motor. Since the motor contin- tion of the fan pump lowers to 0 rpm, the
ues revolution because of the force of inertia, hydraulic oil from the pump is not supplied to
however, the pressure on the outlet side of the port (P) any more. As the hydraulic oil is not
motor rises. supplied to the (MA) side of the motor, the
q When the oil stops flowing in from inlet port (P), motor speed lowers gradually to stop.
suction valve (1) sucks in the oil on the outlet q If the motor shaft is revolved by the force of
side and supplies it to port (MA) where there is inertia while the oil flow in the port (P) is reduc-
not sufficient oil to prevent cavitation. ing, the oil in port (T) on the outlet side is sent
by suction valve (1) to the (MA) side to prevent
Operation cavitation.
1) When pump is started

q When the hydraulic oil from the pump is sup-
plied to port (P) and the pressure on the (MA)
side rises and starting torque is generated in
the motor, the motor starts revolution. The oil
on the outlet (MB) side of the motor returns
through port (T) to the tank.
PC2000-8 45
3. Operation of reversible valve
1) When the ON-OFF solenoid is de-energized 2) When ON-OFF solenoid is energized

q If ON-OFF solenoid (1) is “de-energized”, the q If ON-OFF solenoid (1) is “energized”, ON-
pressurized oil from the pump is blocked by OFF selector valve (2) changes to let the pres-
ON-OFF selector valve (2), and port (C) opens sured oil from the pump flow through port (C)
for the tank circuit. into spool chamber (D).
q Spool (3) is pushed to the right by spring (4). q The pressurized oil in chamber (D) pushes
q Motor port (MA) opens and pressurized oil valve spool (3) to the left against spring (4).
flows in to revolve the motor in forward (clock- q Motor port (MB) opens and pressurized oil
wise). flows in to revolve the motor in reverse (coun-
terclockwise).
46 PC2000-8
4. Safety valve
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) exceeds the cracking
pressure of safety valve (1), valve (2) of safety
valve (1) opens to relieve the oil into port (T).
q By this operation, generation of abnormal pres-
sure in port (P) is prevented.
PC2000-8 47
Cooling fan pump 1

Type: HPV95+95+SBL (1) 21
48 PC2000-8
Outline
q The pump unit is composed of 2 variable-
capacity swash plate-type piston pumps, PC
valves, EPC valves and a single gear pump.
IMF : Front side swash plate control current

IMR : Rear side swash plate control current
PAF : Front pump discharge port
PAG : Gear pump discharge port
PAR : Rear pump discharge port
PBF : Pump pressure output port
PBR : Pump pressure output port
PD1F : Case drain port
PD1R : Air bleeder
PD2F : Drain plug
PD2R : Drain plug
PENF : Control pressure pick-up port
PENR: Control pressure pick-up port
PEPC: EPC basic pressure port
PFC : Front pump discharge pressure pick-up port
PMF : EPC output pressure pick-up port for front
side swash plate control
PMR : EPC output pressure pick-up port for rear
side swash plate control
PPF : Front pump pressure sensor installation port
PPR : Pump pressure sensor installation port
PRC : Rear pump discharge pressure pick-up port
PRF : Pilot pressure input port
PRR : Pilot pressure input port
PS : Pump suction port
PSG : Gear pump suction port
1. Front pump
2. Rear pump
3. Gear pump
4. PC valve
5. EPC valve
6. Sequence valve
PC2000-8 49
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. Servo piston
13. PC valve
50 PC2000-8
Function q Rocker cam (4) conducts high pressure oil to

q The engine speed and torque are transmitted cylinder surface (B) with cradle (2), which is
to the shaft of this pump. Then, this pump con- secured to the case, and forms a static pres-
verts the speed and torque into oil pressure sure bearing when it slides.
and discharges pressurized oil according to q Piston (6) carries out relative movement in the
the load. axial direction inside each cylinder chamber of
q It is possible to change the delivery by chang- cylinder block (7).
ing the swash plate angle. q Cylinder block (7) seals the pressurized oil to
valve plate (8) and carries out relative rotation.
Structure q This surface is designed so that the oil pres-
q Cylinder block (7) is supported to shaft (1) by sure balance is maintained at a suitable level.
spline (14). q The oil inside each cylinder chamber of cylin-
q Shaft (1) is supported by front and rear bear- der block (7) is suctioned and discharged
ings (15). through valve plate (8).
q The end of piston (6) has a spherical hollow
and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
PC2000-8 51
Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves along plate angle = 0), the difference between vol-
cylindrical surface (B), so angle (a) between cen- umes (E) and (F) inside cylinder block (7)
ter line (X) of rocker cam (4) and the axial direc- becomes 0.
tion of cylinder block (7) changes. q Suction and discharge of pressurized oil is not
q Angle (a) is called the swash plate angle. carried out in this state. Namely pumping
action is not performed. (Actually, however, the
swash plate angle is not set to 0)
q With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) sucks and discharges the oil
by amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
52 PC2000-8
Control of delivery
q If swash plate angle (a) becomes larger, the dif-
ference between volumes (E) and (F) becomes
larger and pump delivery (Q) increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pressure
chamber of the small diameter piston side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
PC2000-8 53
1. PC valve
PA : Pump port 1. Plug

PDP : Drain port 2. Servo piston assembly
PM : EPC pressure input port 3. Pin
PPL : Control pressure output port 4. Spool
(To servo piston large diameter end) 5. Retainer
6. Seat
7. Cover
8. Wiring
Function
q The PC valve controls the pump delivery (Q)
according to the EPC valve output pressure
(PM).
q If the EPC valve output pressure (PM) rises,
the PC valve increases the pump delivery (Q).
q If the EPC valve output pressure (PM) lowers,
the PC valve decreases the pump delivery (Q).
54 PC2000-8
1) Action of EPC valve solenoid (1)
Operation
q PC mode selector current (IM) from the pump
controller is conducted to EPC valve solenoid (1).
q PC mode selector current (IM) works on EPC
valve to have it generate the signal pressure in
order to change piston (2) pushing force.
q Spool (3) stops at a position where the force of
spring (4) is balanced with the force applied to
piston (2) according to the EPC valve signal
pressure.
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The level of PC mode selector current (IM) is
determined by the engine oil temperature,
hydraulic oil temperature, engine speed, and
set value of the hydraulic fan.
q The spring set force of spring (4) varies as
servo piston (9) expands and compresses
spring (4).
PC2000-8 55
2) When PC mode selector current is decreased (When EPC output pressure lowers)
q Port (C) of PC valve is connected to the large q The pressure on port (C) rises and the pres-
diameter end of servo piston (9). sure on the large diameter end of the piston
q Pump discharge pressure (PA) is applied to the also rises. Thus, the leftward move of servo
small diameter end of servo piston (9) and port piston (9) is stopped.
(B). q The stop position of servo piston (9) (= pump
q When EPC output pressure (PM) is decreased, delivery) is determined by the position where
spool (3) moves to the left. the pressing force generated by the EPC valve
q Ports (C) is connected to port (D) and the pres- output pressure is balanced with the force of
sure applied to the large diameter end of the spring (4).
piston becomes drain pressure (PT) and servo q When the stop position of servo piston (9) (=
piston (9) moves to the left. pump delivery) is at a middle position between
q The pump delivery will be set to the increasing the maximum and minimum pump delivery
trend. positions, the pressure on the large diameter
q Accompanied with move of servo piston (9), end of the piston is about a half of pump dis-
spring (4) will be expanded and the spring charge pressure (PA). When the former is at
force becomes weaker. the maximum pump delivery position, the latter
q As the spring force is weakened, spool (3) becomes drain pressure (PT).
moves to the right, the connecting between
port (C) and port (D) is shut off and the pump
discharge pressure ports (B) and (C) are con-
nected.
56 PC2000-8
3) When PC mode selector current is increased (When EPC output pressure rises)
Operation q When the stop position of servo piston (9) (=

q When EPC output pressure (PM) is increased, pump delivery) is at a middle position between
spool (3) moves to the right. the maximum and minimum pump delivery
q If ports (C) is connected to port (B), the pres- positions, the pressure on the large diameter
sure on the large diameter end of the piston end of the piston is about a half of pump dis-
rises and servo piston (9) moves to the right. charge pressure (PA). When the former is at
q The pump delivery is decreased. the minimum pump delivery position, the latter
q As servo piston (9) moves, spring (4) is com- becomes pump discharge pressure (PA).
pressed and its force is increased.
q If the spring force is increased, spool (3)
moves to the left, port (C) is disconnected from
port (B), and draining port (D) is connected to
port (C).
q If the pressure in port (C) lowers, the pressure
on the large diameter end of the piston lowers
and consequently servo piston (9) stops mov-
ing to the right.
q The stop position of servo piston (9) (= pump
delivery) is determined by the position where
the pressing force generated by the EPC valve
output pressure is balanced with the force of
spring (4).
PC2000-8 57
q The relationship between PC mode selector

current (IM) and pump delivery (Q) becomes
as shown below.
58 PC2000-8
2. EPC valve
C: To PC valve
P: From pilot relief valve
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
PC2000-8 59
Function Operation
q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion. 1) When signal current is 0 (Coil is de-ener-
q When it receives signal current (i) from the gized)
controller, it generates the EPC output pres- q When there is no signal current flowing from the
sure in proportion to the size of the signal, and controller to coil (2), coil (2) is de-energized.
outputs it to the PC valve. q Spool (5) is pushed to the left by spring (4).
q Port (P) is closed and the pressurized oil from the
pilot relief valve does not flow to the PC valve.
q The pressurized oil from the PC valve is drained
to the tank through port (C) and port (T).
60 PC2000-8
2) When signal current is very small (coil is 3) When signal current is maximum (coil is
energized) energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressures on port (C) increases and the force q Spool (5) is pushed toward the right side by rod
to act on spool (5) surface and the spring load (6).
on spring (4) become larger than the propul- q The maximum volume of pressurized oil is
sion force of plunger (7). conducted from port (P) to port (C), increasing
q Spool (5) is pushed to the left, and port (P) is the circuit pressure across the EPC valve and
shut off from port (C). PC valve to the maximum level.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves so that the propulsion force of not flow to the tank.
plunger (7) may be in balance with pressure of
port (C) + spring load of spring (4).
q The circuit pressure between the EPC valve
and PC valve is controlled in proportion to the
size of the signal current.
PC2000-8 61
SEN01619-00
© 2006 KOMATSU
All Rights Reserved
62
SEN01620-00
PC2000-8

PC2000-8 20001 and up

Travel motor ......................................................................................................................................... 2
Hydraulic pump .................................................................................................................................. 14
PPC valve .......................................................................................................................................... 32
Variable back pressure valve ............................................................................................................. 44
Suction selector valve ........................................................................................................................ 48
PPC cut-off valve ............................................................................................................................... 52
PC2000-8 1

Travel motor 1
Type: KMF340-5
B : Pressure pick-up port Specifications

MA : Pressure pick-up port Type : KMF340-5
MB : Pressure pick-up port Theoretical displacement: 337.2 cm3/rev
PA : From control valve Rated pressure : 32.8 MPa {335 kg/cm2}
PB : From control valve Rated speed : 2,461 rpm
PAI : Pressure pick-up port Brake release pressure : 1.31 MPa {13.4 kg/cm2}
PBI : Pressure pick-up port
T : To tank
2 PC2000-8
4 PC2000-8
1. Output shaft
2. Motor case
3. Piston
4. Cylinder block
5. Valve plate
6. Housing
7. Plate
8. Disc
9. Oil seal
10. Counterbalance valve spool
11. Retainer
12. Brake spring
13. Brake piston
14. Safety valve
15. Check valve
Unit: mm
Free length
16 Check valve spring length load load If damaged or
diameter
deformed,
66.5 × 25.6 45 —
{0.71 kg} {0.67 kg}
520 N
17 Spool return spring 63 × 44.5 61.5 — —
{53 kg}
PC2000-8 5
Operation of parking brake
1) When starting travel
q As the travel lever is operated, pressurized oil

from the pump actuates counterbalance valve
spool (10) to open the parking brake circuit.
q The pressurized oil flows to chamber (e) of
brake piston (13), compressing brake spring
(12) and pushing brake piston (13) to the right.
q Pressing force so far allied to plate (7) and disc
(8) is eliminated. Thus, plate (7) disengages
from disc (8), releasing the brake.
6 PC2000-8
2) When travel is stopped
q When the travel lever is set to the neutral posi- q Returning brake piston (13) reduces flow of the
tion, and counterbalance valve spool (10) pressurized oil with slow return valve (18).
returns to the neutral position, closing the park- q The specified time lag actuates the brake after
ing brake circuit. the machine has been stopped.
q The pressurized oil in chamber (e) of brake
piston (13) keeps flowing through the throttle of
slow return valve (18) until counterbalance
valve spool (10) returns to the neutral.
q As counterbalance valve spool (10) returned to
the neutral, the oil is drained from the throttle
(f) of brake piston (13) to the case.
q Brake piston (13) is pressed by spring (12) to
the left.
q Plate (7) and disc (8) are compressed to each
other, actuating the brake.
PC2000-8 7
Brake valve
q The brake valve is consisted of check valves Operation when pressurized oil is supplied
(1) and (2), counterbalance valve (3) and q Operating the travel lever conducts the pres-
safety valve (4). surized oil from the control valve to port (PA).
q Functions and operations of respective compo- q The pressurized oil pushes open check valve
nents shall conform to the following. (1) and flows through motor inlet port (MA) to
motor outlet port (MB).
1) Counterbalance valve and check valve q Since the motor outlet side is closed by check
valve (2) and spool (3), the pressure on the
Function supply side rises.
q When traveling downhill, the machine travel
speed tends to get faster than the motor
(engine) speed because of the downward force
generated from its own weight.
q If the machine travels with the engine at low
speed, the motor may rotate without load, caus-
ing the machine to run away; resulting in a very
dangerous situation.
q These valves are used to prevent above by
controlling the machine to travel according to
the engine speed (pump delivery).
q The pressurized oil on the supply side flows to

chamber (S1) through orifices (E1) and (E2) of
spool (3).
q As the pressure in chamber (S1) rises above
the spool selector pressure, spool (3) is
pushed to the right.
8 PC2000-8
q Port (MB) and port (PB) are connected, open- Operation of brake during travelling downhill
ing the motor outlet port side and starting the q If indication of the machine runaway is sensed
motor rotating. while travelling downhill, the motor will be
caused to rotate without load to decrease the
inlet side oil pressure.
q Pressure in chamber (S1) is released through
orifices (E1) and (E2).
q When the pressure in chamber (S1) drops
below the spool selector pressure, spool (3) is
returned to the left, in the direction of the arrow
by spring (6), and outlet port (MB) is throttled.
q The pressure at the outlet port side rises, gen-
erating rotation resistance on the motor to pre-
vent the machine from running away.
q The spool moves to a position where the pres-
sure on the outlet port (MB) can be balanced
against the machine's own weight and the inlet
port pressure.
q Oil flow from the outlet circuit is reduced to
ensure the travel speed corresponded to the
pump delivery.
PC2000-8 9
2) Safety valve
(bidirectional 2-stage set safety valve)
Function q As the pressure goes above the set pressure,

q As long as the machine travel is stopped (or it [Difference in areas of circles (D1) and (D2) ×
is travelling downhill), the counterbalance Pressure] compresses spring (2).
valve closes the inlet and outlet circuits of the q Poppet (1) is moved leftward and the pressur-
motor. ized oil flows into chamber (MA) of the oppo-
q Since the motor is rotated by inertial force, site circuit.
pressure in the motor outlet port side is abnor-
mally increased, potentially resulting in dam-
ages on the motor and piping.
q The safety valve releases this abnormal pres-
sure to the inlet port side of the motor in order
to prevent damages to the equipment.
Bidirectional action
(1) When pressure in chamber (MB) has become
high (when rotating clockwise)
q As long as the machine travel is stopped (or it
is travelling downhill), the check valve of coun-
terbalance valve closes chamber (MB) of the
outlet port circuit.
q The motor tries to continue rotation resorting to
inertial force, thus pressure on the outlet port
(MB) is increased.
10 PC2000-8
(2) When pressure in chamber (MA) has become Operation of mechanism for varying set pressure
high (when rotating counterclockwise) (1) When starting travel (high-pressure setting)
q As long as the machine travel is stopped (or it q As the travel lever is operated, the pressurized oil
is travelling downhill), the check valve of coun- from the pump moves spool (10) to the right.
terbalance valve closes chamber (MA) of the q Above opens the pilot circuit to the safety
outlet port circuit. valve, conducting the pressurized oil to cham-
q The motor tries to continue rotation resorting to ber (J) through chamber (G) and passage (H).
inertial force, thus pressure on the outlet port q Piston (3) is pushed rightward, spring (2) is
(MA) is increased. compressed and the set load is increased.
q High pressure is turned on the safety valve,
providing a large tractional force to the valve.
q As the pressure goes above the set pressure,

[Difference in areas of circles (D1) and (D3) ×
Pressure] compresses spring (2).
q Poppet (1) is moved leftward and the pressur-
ized oil flows into chamber (MB) of the oppo-
site circuit.
PC2000-8 11
(2) When travel is stopped (low-pressure setting)

q When the travel lever is set to the neutral, the
pressure in chamber (PA) drops, spool (10)
returns to the neutral position.
q Until spool (10) returns to the neutral, the pres-
surized oil in chamber (J) keeps on flowing
through passage (H) and chamber (G) to
chamber (PA).
q Piston (3) moves to the left side, decreasing
the set load.
q The safety valve is caused to the low pressure
setting, thereby attenuating the shocks when
the speed is reduced.
Safety valve set pressure

High pressure set: 40.2 MPa {410 kg/cm2}
(At start and during travel)
Low pressure set: 27.5 MPa {280 kg/cm2}
(When stopped)
12 PC2000-8
Hydraulic pump 1
Type: HPV375+375
14 PC2000-8
Outline
q The pump unit is composed of 2 variable-
capacity swash plate-type piston pumps, VC
valves, EPC valves and self pressure reducing
valves.
CE1 : Front EPC output pressure pick-up port

CE2 : Rear EPC output pressure pick-up port
CH1 : Front EPC basic pressure pick-up port
CH2 : Rear EPC basic pressure pick-up port
CP1 : Front pump discharge pressure pick-up port
CP2 : Rear pump discharge pressure pick-up port
CPR: Pilot basic pressure pick-up port
CS1 : Front control pressure pick-up port
CS2 : Rear control pressure pick-up port
E1 : Front EPC command current
E2 : Rear EPC command current
P1 : Discharge port
P2 : Discharge port
PF : Self pressure reducing valve basic pressure port
PR3 : Pilot basic pressure input port (succeeding to the inline filter attached to the machine)
PR4 : Pilot basic pressure output port (preceding the inline filter attached to the machine)
PR5 : Pilot basic pressure pick-up port
S : Suction port
T1 : Drain port
T2 : Drain plug
T3 : Drain plug
T4 : Drain plug
T5 : Drain plug
T6 : Air bleeder
T7 : Drain branch piping port
T8 : Drain plug
T9 : Drain plug
T10 : Drain plug
T11 : Drain plug
1. Front pump
2. Rear pump
3. VC valve
4. EPC valve
5. Self pressure reducing valve
6. Filter
PC2000-8 15
16 PC2000-8
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Servo piston
9. Valve plate
10. End cap
11. Rear case
12. Rear shaft
13. Bevel gear
14. Impeller pump
15. Impeller shaft
16. Impeller pinion
PC2000-8 17
Function q Rocker cam (4) brings high pressure oil at cyl-

q The engine speed and torque are transmitted inder surface with cradle (2), which is secured
to the shaft of this pump. Then, this pump con- to the case, and forms a static pressure bear-
verts the speed and torque into oil pressure ing when it slides.
and discharges pressurized oil according to q Piston (6) carries out relative movement in the
the load. axial direction inside each cylinder chamber of
q It is possible to change the delivery by chang- cylinder block (7).
ing the swash plate angle. q Cylinder block (7) seals the pressurized oil to
valve plate (9) and carries out relative rotation.
Structure q This surface is designed so that the oil pres-
q Cylinder block (7) is supported to shaft (1) by sure balance is maintained at a suitable level.
spline (17). q The pressurized oil inside each cylinder cham-
q Shaft (1) is supported by front and rear bear- ber of cylinder block (7) is sucked in and dis-
ings (18). charged through valve plate (9).
q The end of piston (6) has a spherical hollow q Impeller pump (14) and impeller pinion (16) are
and is combined with shoe (5). united by impeller shaft (15) and connected to
q Piston (6) and shoe (5) form a spherical bearing. shaft (1) through bevel gear (13).
q Rocker cam (4) has flat surface (A), and shoe q They rotate along with the shaft. Thus, they
(5) is always pressed against this surface while help supplying the sucked pressurized oil to
sliding in a circular movement. cylinder block (7) and also help sucking it there
by use of centrifugal force.
18 PC2000-8
Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle = 0), the difference between vol-
along cylindrical surface (B), so angle (a) umes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
the ax ial di rec tio n of cy li nder b loc k (7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q Angle (a) is called the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
q With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
PC2000-8 19
Control of delivery
q If the swash plate angle (a) becomes larger, q The relationship in the size of pressure (PH) at
the difference between volumes (E) and (F) the small diameter piston end and pressure
b ec o me s l ar g er a n d pu m p d el i v e r y ( Q ) (PS) at the large diameter piston end, and the
increases. ratio between the area receiving the pressure
q Swash plate angle (a) is changed with servo of the small diameter piston and the large
piston (8). diameter piston controls the movement of
q Servo piston (8) moves in a reciprocal move- servo piston (8).
ment according to the signal pressure from the
pump controller.
q This linear motion is transmitted to rocker cam
(4) through rod (19).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q With servo piston (8), the area receiving the
pressure is different on the left and the right.
The pump discharge pressure (self pressure)
(PH) is constantly led to the pressure chamber
of the small diameter piston end.
q The pressure chamber of the large diameter
piston end is supplied with the VC valve output
pressure (PS).
20 PC2000-8
Pump controller
System diagram
PC2000-8 21
Pump control signal
22 PC2000-8
Servo valve
CE : Control pressure pick-up port 1. VC valve

CH : Servo actuator pressure pick-up port 2. EPC valve
CS : Servo actuator pressure pick-up port 3. Spool
PA : Main pump pressure port 4. Sleeve
PH : Servo actuator port 5. Spring
PR : Servo basic pressure port
PS : Pump control pressure output port
T : Drain port
PC2000-8 23
1. VC valve
Outline Move of servo piston to the maximum side

q VC valve controls servo piston (4) position q As the EPC valve output pressure increases,
(pump delivery) responding to the EPC valve sleeve (2) compresses spring (1) to move
output pressure (controller command current). upward.
q As long as the swash plate angle is set to max-
Operation imum, the large diameter end pressure (PS)
q Sleeve (2) moves to and stops at a position functions as the drain pressure. [The servo pis-
where the EPC valve output pressure and the ton is pushed toward the maximum side by the
force of spring (1) are balanced. small diameter end pressure (PH).]
q The large diameter end pressure is changed q Move of servo piston (4) toward the maximum
by the changes of the opening area on the side is stopped at a position where it contacts
notches (A) and (B) between sleeve (2) and against the MAX adjustment screw (5).
spool (3) plus by the switching of the connec-
tion port. As the result, servo piston (4) is
moved.
24 PC2000-8
Move of servo piston to the minimum side Stop of servo piston move in halfway toward
q As the EPC valve output pressure decreases, the swash plate maximum or minimum position
sleeve (2) elongates spring (1) to move down- q Move of servo piston (4) is feed back to VC
ward. valve by spool (3).
q Opening (B) between sleeve (2) and spool (3) q Move of servo piston (4) changes the space of
opens [Opening (A) closes], connecting the opening of the notch (throttle) between spools
large diameter end port to the shuttle valve (3) and sleeve (2), changing the large diameter
output pressure [= Small diameter end pres- end pressure.
sure (PH)]. Thus, servo piston (4) is moved q Servo piston (4) is stopped as the pressure
toward the minimum side by the difference in ratio between the small diameter piston and
the force resulting from the difference in the large diameter piston becomes 2 : 1 (Ratio of
pressure receiving areas. pressure receiving areas between small diam-
q Move of servo piston (4) toward the minimum eter piston and large diameter piston = 1 : 2).
side is stopped at a position where it contacts
against the MIN adjustment screw (6).
PC2000-8 25
2. Servo piston
Outline Operation of servo piston

q Port (PA) pressure or port (PR) pressure, q When sleeve (4) moves upward, port (PH) is
whichever is higher, is applied to port (PH) by disconnected from port (PS) and port (PS) and
the shuttle valve. port (TD) are connected.
q Relation of pressure receiving area (A) of q Since chamber (a) is connected to drain port
chamber (a) and pressure receiving area (B) of (TD), servo piston (3) is moved to the right by
chamber (b) is expressed as (A) C [2 × (B)]. (PH) pressure.
q Pressure of port (PH) is constantly applied to q When servo piston (3) moves to the right, cam
chamber (b). (6) which is coupled with servo piston (3)
PA : Main pump discharge pressure moves to the right.
PR : Pilot basic pressure q Spool of VC valve (1) moves upward.
PH : PA or PR pressure whichever is higher q When spool of VC valve (1) moves upward,
port (PS) is disconnected from port (TD).
Operation of VC valve q Port (PS) starts connecting to port (PH) and pres-
q The command current from the pump control- sures of chambers (a) and (b) are balanced.
ler is conducted to EPC solenoid (E1). q Servo piston (3) stops its move.
q This command current reduces the control q Move of servo piston (3) changes in proportion to
basic pressure applied to EPC valve (2). the moving distance of sleeve (4) of VC valve (1).
q EPC valve (2) transmits the command current
specified pilot pressure. When EPC valve is not operated
q The pilot pressure goes to chamber (se1) q Sleeve (4) of VC valve (1) does not operate if the
through port (SE1). pilot pressure from EPC valve (2) is not present.
q Sleeve (4) of VC valve (1) is maintained at a q In this case, ports (PH) and (PS) are con-
position where the EPC valve (2) pilot pressure nected and the connection between ports (PS)
and the spring (5) force are balanced. and (TD) is cut off.
q The pump controller controls magnitude of the q Since the pressure in chambers (a) and (b) is
command current sent to EPC valve (2). set to the same level, servo piston (4) is moved
to the left.
q The pump delivery is kept at the minimum.
26 PC2000-8
3. EPC valve
C : To VC valve 1. Body
P : From pump 2. Spool
T : To hydraulic tank 3. Spring
4. Rod
5. Coil
6. Plunger
7. Connector
PC2000-8 27
Function Operation
q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion.
q When it receives signal current (i) from the 1. When signal current is 0 (coil is de-
controller, it generates the EPC output pres- energized)
sure in proportion to the size of the signal, and q When there is no signal current flowing from the
outputs it to the VC valve. controller to coil (5), coil (5) is de-energized.
q Spool (2) is pushed to the right by spring (3).
q Port (P) closes the pressurized oil from the self
pressure reducing valve does not flow to the
control valve.
q The pressurized oil from the VC valve is drained
to the tank through port (C) and port (T).
28 PC2000-8
2. When signal current is very small 3. When signal current is maximum

(coil is energized) (coil is energized)
q When a very small signal current flows to coil q As the signal current flows to coil (5), coil (5) is
(5), coil (5) is energized, and a propulsion force energized.
is generated on the left side of plunger (6). q When this happens, the signal current is at its
q Rod (4) pushes spool (2) to the left, and the maximum, so the propulsion force of plunger
pressurized oil flows from port (P) to port (C). (6) is also at its maximum.
q Pressure on port (C) increases and the force to q Spool (2) is pushed to the left by rod (4).
act on surface (a) of spool (2) + the spring load q The maximum volume of pressurized oil is
on spring (3) become larger than the propul- conducted from port (P) to port (C), increasing
sion force of plunger (6). the circuit pressure across EPC valve and VC
q Spool (2) is pushed to the right, and port (P) is valve to the maximum level.
shut off from port (C). q Since port (T) is closed, pressurized oil does
q Port (C) and port (T) are connected. not flow to the tank.
q Spool (2) moves up and down so that the pro-
pulsion force of plunger (6) may be balanced
with pressure of port (C) + the spring load of
spring (3).
q The circuit pressure between the EPC valve
and the VC valve is controlled in proportion to
the size of the signal current.
PC2000-8 29
Self pressure reducing valve
Function 2. Fan pump discharge pressure (P3F)

q This valve reduces the discharge pressure of the is reduced
fan pump and supplies it as the control pressure a When the load pressure (P3) is lower than output
for the solenoid valve, EPC valve, etc. pressure (PR) of self pressure reducing valve
Operation q Valve (1) receives the force of spring (2) and

pressure (PR) (which is {0 MPa {0 kg/cm 2 }
1. When engine is stopped when engine is stopped) in the direction to
q Since poppet (4) is pressed against the seat by close the circuit between ports (P3F) and (P3).
spring (3), the portion of the circuit from port q As the pressurized oil flows in from port (P3F),
(PR) to port (T) is cut off. following balance is reached: [(φd area × P3F
q Since valve (6) is pressed to the left by spring pressure) = the force of spring (2) + (φd area ×
(5), the portion of the circuit from port (P3F) to PR pressure)].
port (PR) is open. q Opening of valve (1) is adjusted to maintain
q Since valve (1) is pressed to the left by spring pressure (P3F) at a constant pressure above
(2), the portion of the circuit from port (P3F) to pressure (PR).
port (P3) is closed. q As (PR) pressure reaches a level higher than
the set pressure, poppet (4) opens.
q The pressurized oil flows from port (PR) to inter-
nal orifice (a) of spool (6) and then flows to tank
drain port (T) through the opening of poppet (4).
q The differential pressure is generated through
internal orifice (a) of spool (6), actuating spool (6)
to close the opening from port (P3F) to (PR).
q Referencing the given open area, the self pres-
sure reducing valve reduces pressure (P3F) to
a specific level (set pressure) in order to supply
the difference as pressure (PR).
30 PC2000-8
3. When load pressure (P3F) is high 4. When abnormally high pressure is

q Change in the fan revolution speed increases generated
load pressure (P3) and, as the result, pump q If pressure (PR) of the self pressure reducing
delivery is increased. valve turns to an abnormally high pressure,
q Since pressure (P3F) increases, [(φd area × valve (1) compresses spring (2).
P3F pressure) > the force of spring (2) + (φd q Port (A) opens and ports (PR) and (TS) are
area × PR pressure)]. As the result, valve (1) is connected.
moved to the right up to the stroke end. q Allows the pressurized oil to (TS) from port
q Since the opening between ports (P3F) and (PR) and lowers pressure (PR).
(P3) increases, resistance along the passage q Protects PPC valve, solenoid valve and other
is reduced and the loss horsepower of the devices from abnormal pressure.
engine is reduced.
q As pressure (PR) reaches a level higher than
the set pressure, poppet (4) opens.
q The pressurized oil flows from port (PR) to
internal orifice (a) of spool (6) and then flows to
tank drain port (T) through the opening of pop-
pet (4).
q The differential pressure is generated through
internal orifice (a) of spool (6), actuating spool
(6) to close the opening from port (P3F) to
(PR).
q The self pressure reducing valve reduces pres-
sure (P3F) to a specific level (set pressure) in
order to supply the difference as pressure
(PR).
PC2000-8 31
PPC valve 1
Work equipment and swing PPC valve 1
P : From self pressure reducing valve

P1 : Left PPC valve: Arm OUT/Right PPC valve: Boom LOWER
P2 : Left PPC valve: Arm IN/Right PPC valve: Boom RAISE
P3 : Left PPC valve: Swing LEFT/Right PPC valve: Bucket CURL
P4 : Left PPC valve: Swing RIGHT/Right PPC valve: Bucket DUMP
T : To tank
32 PC2000-8
34 PC2000-8
1. Spool
2. Piston
3. Disc
4. Nut (for connection of lever)
5. Joint
6. Plate
7. Retainer
8. Body
Unit: mm
Free length
Centering spring × outside Free length
9 length load load
(For ports P3 and P4) diameter
If damaged or
11.8 N 9.41 N
45.85 × 15.5 34.0 — deformed,
{1.2 kg} {0.96 kg}
replace spring
Centering spring 3.92 N 3.14 N
10 37.95 × 15.5 34.0 —
(For ports P1 and P2) {0.4 kg} {0.32 kg}
26.3 N 21.0 N
11 Metering spring 27.08 × 8.14 24.9 —
{2.68 kg} {2.14 kg}
PC2000-8 35
Operation 2. During fine control

(Neutral o fine control)
1. When in neutral q When piston (4) is pushed by disc (5), retainer
q Ports (A) and (B) of the control valve and ports (9) is pushed, spool (1) is also pushed by
(P1) and (P2) of PPC valve are connected to metering spring (2), and moves down.
drain chamber (D) at the bottom. q If port (P1) is disconnected from drain chamber
(D), it connects, almost in that instant, to pump
pressure chamber (PP).
q Pilot pressurized oil of the control pump is con-
ducted from port (P1) to port (A).
q When the pressure at port (P1) becomes higher,
spool (1) is pushed back and port (P1) is shut off
from pump pressure chamber (PP). At almost the
same time, it is connected to drain chamber (D)
to release the pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
q The relationship of the position of spool (1) and
body (10) does not change until retainer (9)
contacts spool (1).
q Metering spring (2) contracts in proportion to
the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force
of the return spring of the control valve spool
are balanced.
36 PC2000-8
3. During fine control 4. At full stroke

(When control lever is returned) q Disc (5) pushes down piston (4), and retainer
q When disc (5) starts to be returned, spool (1) is (9) pushes down spool (1).
pushed up by the force of centering spring (3) q Port (P1) is disconnected from drain chamber
and the pressure at port (P1). (D) and connected to pump pressure chamber
q Port (P1) is connected to drain chamber (D), (PP).
and the pressurized oil of port (P1) is released. q The pilot pressurized oil from the self pressure
q If the pressure of port (P1) is lowered exces- reducing valve is conducted from port (P1) to
sively, spool (1) is pushed down by metering chamber (A) to push the control valve spool.
spring (2). q Return oil from chamber (B) flows from port
q Port (P1) is disconnected from drain chamber (P2) to drain chamber (D).
(D) and then, almost in that instant, connected
to pump pressure chamber (PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns, oil
in drain chamber (D) flows in from the valve on
the side that is not working. The oil passes
through port (P2) and enters chamber (B) to fill
the chamber with the pressurized oil.
PC2000-8 37
Travel PPC valve 1
P : From self pressure reducing valve

P1 : L.H. reverse
P2 : L.H. forward
P3 : R.H. reverse
P4 : R.H. forward
T : To tank
38 PC2000-8
40 PC2000-8
1. Plate
2. Body
3. Piston
4. Seal
5. Centering spring
6. Metering spring
7. Valve
8. Damper
Unit: mm
Free length
9 Centering spring length load load If damaged or
diameter
deformed,
108 N 86.3 N replace spring
47.6 × 15.5 32.5 —
{11.0 kg} {8.8 kg}
16.7 N 13.7 N
10 Metering spring 26.5 × 8.15 24.9 —
{1.7 kg} {1.4 kg}
PC2000-8 41
Operation q The relationship of the position of spool (1) and

body (10) [fine control hole (f) is in the middle
1. When in neutral between drain chamber (D) and pump pres-
q Ports (A) and (B) of the control valve and ports sure chamber (PP)] does not change until
(P1) and (P2) of the PPC valve are connected retainer (9) contacts spool (1).
to drain chamber (D) through fine control hole q Metering spring (2) contracts in proportion to
(f) in spool (1). the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force
of the return spring of the control valve spool
are balanced.
2. During fine control

q When piston (4) is pushed by lever (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1) through fine control
hole (f).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
42 PC2000-8
3. During fine control 4. At full stroke

(When control lever is returned) q Lever (5) pushes down piston (4), and retainer
q When lever (5) starts to be returned, spool (1) (9) pushes down spool (1).
is pushed up by the force of centering spring q Fine control hole (f) is shut off from drain
(3) and pressure at port (P1). chamber (D), and is interconnected to pump
q Because of this, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D), and the pressur- q Therefore, the pilot pressure oil from the self
ized oil at port (P1) is released. pressure reducing valve passes through fine
q If the pressure of port (P1) is lowered exces- control hole (f) and flows to chamber (A) from
sively, spool (1) is pushed down by metering port (P1) to push the control valve spool.
spring (2). q The oil returning from chamber (B) passes
q Fine control hole (f) is shut off from drain cham- from port (P2) through fine control hole (f') and
ber (D), and it is almost simultaneously intercon- flows to drain chamber (D).
nected to pump pressure chamber (PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the cham-
ber with pressurized oil.
PC2000-8 43
Variable back pressure valve 1
TA : From main valve port (T) PI : From solenoid valve

TB : To oil cooler TS : To tank
1. Block
2. Valve
Unit: mm
Free length ×
Installed Installed
outside Installed load Free length
3 Valve return spring length load If damaged or
diameter
deformed,
1,370 N 1,098 N replace spring
187.48 × 38.5 130 —
{140 kg} {112 kg}
231 N 185 N
4 Valve return spring 116.18 × 19.5 90 —
{23.6 kg} {18.9 kg}
44 PC2000-8
1. When travel operation or swing operation is turned on
Function
q In the travel operation or swing operation, back
pressure must be generated in the drain circuit
in order to prevent cavitation.
q In order to reduce power loss, back pressure
must be reduced in the drain circuit for any
operation other than the travel and swing.
Operation
q The pressure is not generated in pilot circuit (a)
since pressurized oil is not fed from solenoid
valve (4).
q The pressurized oil from the main valve works
on the left end face (AB) of valve (1) to gener-
ate back pressure in drain circuit (b) by actuat-
ing springs (2) and (3).
PC2000-8 45
2. In an operation other than travel or swing
Operation
q The pressurized oil being led from solenoid
valve (4) to pilot circuit (a) works on the left
toric surface (Aa) of valve (1) to push springs
(2) and (3).
q The back pressure in drain circuit (b) that is
generated by pressurized oil from main valve
goes low due to the right stroke of valve (1).
46 PC2000-8
Suction selector valve 1
48 PC2000-8
C1 : To bucket CURL (Pilot port of control valve)

C2 : To bucket DUMP (Pilot port of control valve)
C3 : To arm IN (Pilot port of control valve)
C4 : To arm OUT (Pilot port of control valve)
C5 : To boom RAISE (Pilot port of control valve)
C6 : To boom LOWER (Pilot port of control valve)
PP1 : From R.H. PPC valve (Bucket CURL port)
PP2 : From R.H. PPC valve (Bucket DUMP port)
PP3 : From L.H. PPC valve (Arm IN port)
PP4 : From L.H. PPC valve (Arm OUT port)
PP5 : From R.H. PPC valve (Boom RAISE port)
PP6 : From R.H. PPC valve (Boom LOWER port)
PP1 : From R.H. PPC valve (Tank port)
PP2 : From L.H. PPC valve (Tank port)
T : To hydraulic tank
1. Spool
2. Body
3. Flange
4. Retainer
5. O-ring
Unit: mm
Free length
Installed Installed Installed If damaged or
6 Centering spring length load load deformed,
diameter
replace spring
14.7 N 11.8 N
31.72 × 17 24 —
{1.5 kg} {1.2 kg}
PC2000-8 49
Operation 2. During fine control

1. When in neutral q Operating lever (3) conducts the pilot pressur-
q Ports (A) and (B) of control valve (6) and ports ized oil to chamber (E1) through ports (P1) and
(C1), (C2) and (PT1) of suction selector valve (PP1).
(1) are connected to the hydraulic tank through q As the pressure in chamber (E1), which is
port (T) of selector valve (1). used to press spool (4) of selector valve (1),
q Ports (PP1) and (PP2) of selector valve (1) and goes larger than the opposing force of spring
ports (P1) and (P2) of PPC valve (2) are con- (5), spool (4) is actuated and opens the circuit
nected to drain chamber (D). from port (PP1) to port (C1).
q Spool (7) of control valve (6) moves to a posi-
tion where the pressure in chamber (A) [equal
to the pressure in port (P1)] is balanced
against the force of spool return spring (8) of
control valve (6).
q Return oil from chamber (B) of control valve (6)
is returned to the tank from port (T) of selector
valve (1).
50 PC2000-8
3. During fine control

(Fine control o neutral)
q Returning lever (3) to the neutral decreases
port (P1) pressure of PPC valve [equal to
chamber (A) pressure], returning spool (7) of
control valve (6) to the neutral.
q The pressurized oil to be sucked by chamber
(B) of control valve (6) is supplied from port (T)
of selector valve (1).
q As pressure of ports (PP1) and (E1) goes low,
the load of spring (5) increases and spool (4)
returns to the neutral.
PC2000-8 51
PPC cut-off valve 1

1. For straight travel and swing priority
52 PC2000-8
AIN : From boom RAISE port of PPC valve

AOUT1: To R2 valve port (PB22) and L2 valve port (PA22)
AOUT2: To R1 valve port (PA21) and L1 valve port (PA21)
AOUT3: –
BIN : From bucket CURL port of PPC valve
BOUT1: To R2 valve port (PA32) and L2 valve port (PA32)
BOUT2: To L1 valve port (PA31)
BOUT3: To R1 valve port (PA31)
CIN : From arm IN port of PPC valve
COUT1: To R2 valve port (PA12) and L2 valve port (PA12)
COUT2: To L1 valve port (PA11)
COUT3: To R1 valve port (PA11)
DIN : From arm OUT port of PPC valve
DOUT1: To R2 valve port (PB12) and L2 valve port (PB12)
DOUT2: To L1 valve port (PB11)
DOUT3: To R1 valve port (PB11)
EIN : From bucket DUMP port of PPC valve
EOUT1: To R2 valve port (PB32) and L2 valve port (PB32)
EOUT2: To L1 valve port (PB31)
EOUT3: To R1 valve port (PB31)
PI1 : From solenoid valve
PI2 : From solenoid valve
T1 : To tank
T2 : To tank
1. Block
2. Spool
3. Block
4. Spool
Unit: mm
Free length
5 Spring length load load deformed,
diameter
replace spring
320 N 256 N
66.6 × 26.5 57.3 —
{32.7 kg} {26.2 kg}
PC2000-8 53
2. For straight travel
54 PC2000-8
AIN : From R.H. travel reverse port of PPC valve

AOUT1: To R1 valve port (PA51)
AOUT2: To R2 valve port (PA52)
BIN : From L.H. travel reverse port of PPC valve
CIN : From L.H. travel forward port of PPC valve
COUT1: To L1 valve port (PB51)
COUT2: To L2 valve port (PB52)
DIN : From R.H. travel forward port of PPC valve
EIN : From boom LOWER port of PPC valve
EOUT1: To R2 valve port (PB22)
EOUT2: To L1 valve port (PB21)
PI : From solenoid valve
T : To tank
1. Block
2. Spool
3. Block
Unit: mm
Basic dimensions Repair limit
Free length
4 Spring length load load deformed,
diameter
replace spring
320 N 256 N
66.6 × 26.5 57.3 —
{32.7 kg} {26.2 kg}
PC2000-8 55
Swing priority function
1. When operating work equipment (Arm, bucket and boom RAISE)
Operation
q The solenoid valve of the swing priority valve
does not output the pilot pressure. Swing prior-
ity valve (CV2) and selector valve (PV2) stay at
the neutral position.
q The pilot pressure from the bucket PPC valve
and arm PPC valve is led to R1 valve.
q The arm spool and bucket spool of R1 valve is
actuated by the above pressure.
q The boom throttle valve remains not actuated.
56 PC2000-8
2. Simultaneous operation of swing and work equipment

[Swing + Work equipment (Arm, bucket or boom RAISE)]
Operation
q Swing priority valve (CV2) and selector valve
(PV2) are switched by the pilot pressure from
the solenoid valve of the swing priority valve.
q The pilot pressure from bucket PPC valve and
arm PPC valve is cut off by the swing priority
valve.
q The arm spool and bucket spool of R1 valve
remain not actuated. The pilot pressure is con-
ducted to the swing spool.
q In the boom raise operation, the boom throttle
valve is actuated. Thus, the pressure keeps on
flowing to the swing spool.
PC2000-8 57
Straight-travel function
1. In boom, arm, bucket or swing operation excluding travel
Operation
q The solenoid valve of the straight travel valve
does not output the pilot pressure. The straight
travel valve spool stays at the neutral position.
q The pilot pressure from arm PPC valve, boom
PPC valve, bucket PPC valve, and L.H. and
R.H. travel PPC valves is led to L1 valve, L2
valve, R1 valve and R2 valve.
q Respective spools of L1 valve travel, L2 valve
bucket, boom, arm, R1 valve travel, R2 valve
bucket, boom, arm are actuated.
58 PC2000-8
2. In travel + operation (Boom, arm, bucket or swing)
Operation q L2 and R2 valves are actuated for the indepen-

q Both spools (CV1) and (CV2) of the straight dent L.H. or R.H. operation and L1 and R1
travel valve are switched by the pilot pressure valves are actuated for the operations other
from the solenoid valve of the straight travel than travel.
valve. q Any change in the work equipment operation
q Respective spools remain not actuated since (boom RAISE o boom LOWER, for instance)
the pilot pressure from arm, boom, bucket, during this period does not change the flow
R.H. and L.H. travel PPC valves is cut off. rate to the R.H. and L.H. travel. Thus, the
q Arm PPC valve: L2 valve and R2 valve straight traveling function of the machine is
q Boom PPC valve: L2 valve and R2 valve maintained.
q Bucket PPC valve: L2 valve and R2 valve
q R.H. and L.H. travel PPC valves: L1 valve
and R1 valve
PC2000-8 59
SEN01620-00
© 2006 KOMATSU
All Rights Reserved
60
SEN01621-00
PC2000-8

PC2000-8 20001 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Work equipment ................................................................................................................................... 2
Dimensions of work equipment ............................................................................................................ 4
PC2000-8 1
Work equipment 1
Work equipment 1
2 PC2000-8
Unit: mm
Clearance between size clearance limit
Shaft Hole
1 boom-revolving frame
mounting pin and bushing –0.043 +0.456 0.386 –
160 1.5
–0.106 +0.343 0.562
Clearance between
–0.043 +0.172 0.128 –
2 boom-revolving frame 160 2.5
–0.106 +0.085 0.278
mounting pin and bushing
Clearance between
–0.043 +0.174 0.128 –
3 boom cylinder-revolving frame 180 3.5
–0.106 +0.085 0.280
Clearance between
–0.043 +0.160 0.128 –
4 boom-boom cylinder head 180 4.5
–0.106 +0.085 0.266
Clearance between
–0.043 +0.166 0.128 –
5 boom-boom cylinder head 180 5.5
–0.106 +0.085 0.272
Clearance between
–0.043 +0.172 0.128 –
6 boom-arm cylinder mounting 140 6.5
–0.106 +0.085 0.278
pin and bushing
Clearance between boom-arm –0.050 +0.581 0.520 –
7 200 7.5
mounting pin and bushing –0.122 +0.470 0.703
Clearance between boom-arm –0.050 +0.783 0.710 –
8 200 8.5
Clearance between Replace
–0.043 +0.172 0.128 –
9 arm-arm cylinder mounting pin 140 9.5
–0.106 +0.085 0.278
and bushing
Clearance between
–0.036 +0.190 0.121 –
10 arm-bucket cylinder mounting 120 10.5
–0.090 +0.085 0.280
pin and bushing
Clearance between
–0.043 +0.408 0.335 –
11 link-bucket mounting pin and 140 11.5
–0.106 +0.292 0.514
bushing
Clearance between
–0.043 +0.2 0.043 –
12 link-bucket mounting pin and 140 12.5
–0.106 +0.0 0.306
bushing
Clearance between
–0.043 +0.393 0.349 –
13 bucket cylinder-link mounting 140 13.5
–0.106 +0.306 0.499
pin and bushing
Clearance between
–0.043 +0.1 0.043 –
14 bucket cylinder-link mounting 140 14.5
–0.106 +0.1 0.206
pin and bushing
Clearance between arm-link –0.043 +0.430 0.342 –
15 140 15.5
Clearance between arm-link –0.043 +0.1 0.043 –
16 140 16.5
Clearance between
–0.043 +0.421 0.382 –
17 arm-bucket mounting pin and 140 17.5
–0.106 +0.339 0.527
bushing
PC2000-8 3
Dimensions of work equipment 1

1. Arm
4 PC2000-8
Unit: mm
PC2000-8
No.
3.9 m arm
1 140
2 110
3 936
4 200
5 489
6 672.8
7 1199
8 3,841.7
9 5,103
10 719
11 1,300
12 1,210
13 955
14 3,900
15 140
16 364
17 140
Arm as individual part 348
18
When press-fitting bushing 364
Min. 3,250
19
Max. 5,420
20 124
PC2000-8 5
2. Bucket
6 PC2000-8
Unit: mm
PC2000-8
No.
12 m3 bucket
1 940
2 170
3 100°
4 955
5 3069
6 518
7 1322
8 410
9 330
10 165
11 71
12 86
13 20
14 365
15 370
16 98
17 88
18 218
19 233
20 R180
21 R130
22 φ160
23 φ185
24 φ140
25 φ326
26 φ220
27 25°
28 134
29 55
30 φ248
31 12 × M36 × 3 THROUGH
32 45°
33 45°
34 22.5°
PC2000-8 7
SEN01621-00
© 2006 KOMATSU
All Rights Reserved
8
SEN01622-00
PC2000-8

PC2000-8 20001 and up

Cab and its attachments
Cab and its attachments ................................................................................................................................. 2
Air conditioner piping............................................................................................................................ 2
Cab....................................................................................................................................................... 3
PC2000-8 1
Cab and its attachments 1

Air conditioner piping 1
1. Duct
2. Condenser
3. Air conditioner compressor
4. Hot water return piping
5. Hot water pickup piping
6. Refrigerant piping
7. Receiver tank
8. Air conditioner unit
A : Fresh air
B : Recirculated air
C : Hot air/cold air
2 PC2000-8
Cab 1
Wiper system
1. Washer tank
2. Washer hose
3. Lower wiper motor
4. Lower wiper blade, wiper
5. Upper wiper motor
6. Upper wiper blade, wiper
7. Proximity switch
8. Wiper relay
9. Controller
10. Machine monitor
PC2000-8 3
Wiper system
Function
q The wipers can be driven in the 3 modes of intermittent, continuous and continuous (only upper wiper)
with the machine monitor.
q The large wipers are used to wipe wider area of the window. The wiping ranges of the upper and lower
wipers are overlapped to eliminate an unwiped part.
q The controller receives the sensing signal from the proximity switch and the contact signals from the
wiper motors and operates the wiper motors separately through the wiper relays so that the upper and
lower wiper will not interfere with each other.
q When the wipers are operated, the wiper drive relays are shorted to supply the battery power to the
wiper motors.
q When the wipers are stopped, the wiper brake relays are shorted to connect the inverse current from the
wiper motors to the ground to brake the motors.
4 PC2000-8
PC2000-8 5
SEN01622-00
© 2006 KOMATSU
All Rights Reserved
6
SEN01623-00
PC2000-8

PC2000-8 20001 and up

Electrical system
Electrical system ............................................................................................................................................. 2
Engine control ...................................................................................................................................... 2
Electrical control system .................................................................................................................... 13
Monitor system................................................................................................................................... 55
Sensor................................................................................................................................................ 83
ORBCOMM terminal .......................................................................................................................... 95
PC2000-8 1
Electrical system 1
Engine control 1
Operation of system
Starting engine
q If the starting switch is turned to the “START” position, the engine controller checks the state that the
engine stop switch is OFF and the lock lever is reset and the hydraulic tank strainer is installed and sup-
plies the start signal to the starting motor and then the starting motor rotates to start the engine.
At this time, the engine controller checks the signal voltage from the fuel control dial and controls the
engine speed to the set speed.
2 PC2000-8
Engine speed control

q The fuel control dial sends the signal voltage according to the set engine speed.
q The pump controller receives the information of the fuel control dial position from the engine controller
through the network.
q The pump controller calculates proper engine speed for the working mode, deceleration state, etc. and
outputs commands to the engine controller.
q The engine controller decides the fuel injection rate according to the commands from the pump control-
ler.
PC2000-8 3
Stopping engine
q If the engine controller senses that the starting switch or the engine stop switch is set in the “STOP”
position, it stops fuel injection to stop the engine.
4 PC2000-8
Component
Fuel control dial
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
Function
q A potentiometer is installed under the knob. As
the knob is turned, the potentiometer shaft is
turned.
q As the potentiometer shaft is turned, the resis-
tance of the variable resistor in potentiometer
(5) changes and a throttle signal is sent to the
engine controller.
q The hatched area in the graph shown at right is
the abnormality detection area.
While the throttle voltage is in this area, the
engine speed is in low idle.
PC2000-8 5
Engine controller, left bank
Input and output signals CN-CE01

q Meanings of signal classes in the terminal table Input/
Pin No. Signal name
shown below are as follows. output
A: Power supply 11 NC(*) —
B: Input 12 NC(*) —
C: Ground/Shield/Return 13 Engine oil pressure sensor B
D: Output 14 NC(*) —
E: Communication 15 Coolant temperature sensor B
CN-CE01 16 5V electric power supply for sensor A
Input/ 17 Engine oil level sensor B
Pin No. Signal name 18 NC(*) —
output
1 NC(*) — 19 NC(*) —
2 NC(*) — 20 NC(*) —
3 Atmosphere sensor B 21 NC(*) —
4 Supply pump #1 (+) D 22 NC(*) —
5 Supply pump #1 (–) C 23 Boost temperature sensor B
6 CAN (–) E 24 NC(*) —
7 NC (*) — 25 Common rail pressure sensor B
8 CAN (+) E 26 Bkup sensor (+) B
9 Supply pump #2 (–) D 27 NE sensor (+) B
10 Supply pump #2 (–) C *: Never connect to NC or malfunctions or failures will
*: Never connect to NC or malfunctions or failures will occur.
occur.
6 PC2000-8
CN-CE01 CN-CE02
Input/ Input/
Pin No. Signal name Pin No. Signal name
output output
28 NC(*) — 13 NC(*) —
29 NC(*) — 14 NC(*) —
30 Fuel temperature sensor B 15 NC(*) —
31 NC(*) — 16 NC(*) —
32 NC(*) — 17 NC(*) —
33 5 V electric power supply for sensor A 18 NC(*) —
34 NC(*) — 19 NC(*) —
35 NC(*) — 20 NC(*) —
36 NC(*) — 21 NC(*) —
37 5 V electric power supply for sensor A 22 Fuel control dial (+5V) A
38 GND C 23 Fuel control dial (–) C
39 NC(*) — 24 NC(*) —
40 NC(*) — 25 NC(*) —
41 NC(*) — 26 NC(*) —
42 NC(*) C 27 NC(*) —
43 Intake temperature sensor B 28 NC(*) —
44 Boost pressure sensor B 29 NC(*) —
45 Injector #1 (+) D 30 NC(*) —
46 Injector #5 (+) D 31 NC(*) —
47 Sensor GND C 32 NC(*) —
48 Ne sensor (–) C 33 NC(*) —
49 NC(*) — 34 GND C
50 NC(*) — 35 NC(*) —
51 Injector #2 (–) C 36 NC(*) —
52 Injector #3 (–) C 37 NC(*) —
53 Injector #1 (–) C 38 NC(*) —
54 Injector #2 (+) D 39 Key switch (ACC) B
55 Injector #3 (+) D 40 Electrical intake air heater relay drive D
56 Injector #4 (+) D 41 NC(*) —
57 Injector #6 (+) D 42 Electrical intake air heater relay GND C
58 Injector #4 (–) C 43 NC(*) —
59 Injector #6 (–) C 44 NC(*) —
60 Injector #5 (–) C 45 NC(*) —
*: Never connect to NC or malfunctions or failures will 46 CAN(+) E
occur. 47 CAN(–) E
48 NC(*) —
CN-CE02 49 NC(*) —
Input/ 50 NC(*) —
Pin No. Signal name
output *: Never connect to NC or malfunctions or failures will
1 NC(*) — occur.
2 NC(*) —
3 NC(*) — CN-CE03
4 NC(*) — Input/
Pin No. Signal name
5 NC(*) — output
6 NC(*) — 1 GND C
7 Model selection B 2 NC(*) —
8 NC(*) — Electric power supply
3 A
9 Fuel control dial (+) B (+24V constantly)
10 NC(*) — 4 NC(*) —
11 NC(*) — *: Never connect to NC or malfunctions or failures will
12 NC(*) — occur.
*: Never connect to NC or malfunctions or failures will
occur.
PC2000-8 7
Engine controller, right bank
Input and output signals CN-CE01

q Meanings of signal classes in the terminal Input/
Pin No. Signal name
table shown below are as follows. output
A: Power supply 11 NC(*) —
B: Input 12 NC(*) —
C: Ground/Shield/Return 13 NC(*) —
D: Output 14 NC(*) —
E: Communication 15 NC(*) —
CN-CE01 16 NC(*) —
Input/ 17 NC(*) —
Pin No. Signal name 18 NC(*) —
output
1 NC(*) — 19 NC(*) —
2 NC(*) — 20 NC(*) —
3 NC(*) — 21 NC(*) —
4 Right bank supply pump #1 (+) D 22 NC(*) —
5 Right bank supply pump #1 (–) C 23 NC(*) —
6 CAN (–) E 24 NC(*) —
7 NC (*) — 25 Common rail pressure sensor B
8 CAN (+) E 26 Bkup sensor (+) B
9 Right bank supply pump #2 (+) D 27 NE sensor (+) B
10 Right bank supply pump #2 (–) C *: Never connect to NC or malfunctions or failures will
*: Never connect to NC or malfunctions or failures will occur.
occur.
8 PC2000-8
CN-CE01 CN-CE02
Input/ Input/
output output
28 NC(*) — 13 NC(*) —
29 NC(*) — 14 NC(*) —
30 Fuel temperature sensor B 15 NC(*) —
31 NC(*) — 16 NC(*) —
32 NC(*) — 17 NC(*) —
34 NC(*) — 19 NC(*) —
35 NC(*) A 20 NC(*) —
36 NC(*) — 21 NC(*) —
38 NC(*) — 23 NC(*) —
39 NC(*) — 24 NC(*) —
40 NC(*) — 25 NC(*) —
41 NC(*) — 26 NC(*) —
42 NC(*) — 27 NC(*) —
43 NC(*) — 28 NC(*) —
44 NC(*) — 29 NC(*) —
45 Injector #1 (+) D 30 NC(*) —
46 Injector #5 (+) D 31 NC(*) —
47 Sensor GND — 32 NC(*) —
48 Ne sensor (–) C 33 NC(*) —
49 NC(*) — 34 GND C
50 NC(*) — 35 NC(*) —
51 Injector #2 (–) C 36 NC(*) —
52 Injector #3 (–) C 37 NC(*) —
53 Injector #1 (–) C 38 NC(*) —
54 Injector #2 (+) D 39 Key switch (ACC) B
55 Injector #3 (+) D 40 NC(*) —
56 Injector #4 (+) D 41 NC(*) D
57 Injector #6 (+) D 42 NC(*) —
58 Injector #4 (–) C 43 NC(*) —
59 Injector #6 (–) C 44 NC(*) —
60 Injector #5 (–) C 45 NC(*) —
*: Never connect to NC or malfunctions or failures will 46 CAN(+) E
occur. 47 CAN(–) E
48 NC(*) —
CN-CE02 49 NC(*) —
Input/ 50 NC(*) —
Pin No. Signal name
output *: Never connect to NC or malfunctions or failures will
1 NC(*) — occur.
2 NC(*) —
3 NC(*) — CN-CE03
4 NC(*) — Input/
Pin No. Signal name
5 NC(*) — output
6 NC(*) — 1 GND C
7 NC(*) — 2 NC(*) —
8 Model selection B Electric power supply
3 A
9 NC(*) — (+24V constantly)
10 NC(*) — 4 NC(*) —
11 NC(*) — *: Never connect to NC or malfunctions or failures will
12 NC(*) — occur.
*: Never connect to NC or malfunctions or failures will
occur.
PC2000-8 9
Fuel temperature sensor NE speed sensor (Crank angle sensor)

q The fuel temperature sensor senses the fuel q If the signal hole made on the flywheel passes
temperature and sends it to the engine control- the sensor, the magnetic line of force changes.
ler. The sensor unit is a thermistor, the resis- q If the magnetic line of force changes, the out-
tance of which changes according to the put of the Hall element sensor changes linearly
temperature. and it is converted into pulse of 0 – 5 V by the
q The engine throttle controller applies voltage to wave form shaping circuit in the sensor, and
the thermistor and senses the temperature by then output.
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
Atmospheric pressure sensor

q This sensor is used to correct altitude.
Common rail pressure sensor, oil pressure

sensor
10 PC2000-8
Bkup speed sensor (G sensor) Boost temperature sensor

q Similarly to the NE speed sensor, this sensor q The boost temperature sensor senses the
utilizes the pulses of 0 – 5 V generated by the intake air temperature (charge temperature)
change of the magnetic line of force crossing and sends it to the engine controller.
the sensor unit. q The sensor unit is a thermistor, the resistance
q The disc gear installed to the central part of the of which changes according to the tempera-
camshaft of the high-pressure pump has teeth ture. The engine controller applies voltage to
(cut parts) around it at intervals of 120°. the thermistor and senses the temperature by
q In addition to the above teeth, one more tooth the voltage divided by the resistance in the
is installed. Accordingly, 7 pulses are gener- computer and the resistance of the thermistor.
ated every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
Boost pressure sensor

q This sensor is used to sense the boost pres-
sure (charge pressure).
PC2000-8 11
Coolant temperature sensor

• The coolant temperature sensor senses the
coolant temperature and sends it to the engine
controller.
• The sensor unit is a thermistor the resistance of
which changes according to the temperature.
The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the compu-
ter and the resistance of the thermistor.
12 PC2000-8
Electrical control system 1
Engine output control function

Engine and pump compound
control function
Pump absorption torque control function
Auto-deceleration function OFF (Reset)

Auto-low idle function
ON
NC flow control
Electronic CLSS function PC characteristic flow control
Cut-off control
Cut-off reset
Emergency pump drive
Heavy lift function OFF (Reset)
ON
2-stage boom pushing force ON (High digging performance mode)

selector function
OFF (Machine push-up mode)
Swing control function

Electrical control
system
Engine automatic warming-up,
overheat prevention function,
turbo protect function, split
injection function
Boom shockless control function OFF (Reset)
ON
Straight travel function
Compound operation
compensation function
Variable back pressure

compensation function
Hydraulic fan control function
14
Fan reverse function
PC2000-8 13
System diagram
14 PC2000-8
PC2000-8 15
Engine and pump compound control function
16 PC2000-8
Function q The pump controller selects a proper engine

With this function, the engine output and pump output curve and pump absorption torque
absorption torque are controlled properly and according to the operation pattern.
excessive fuel consumption is reduced by using q The engine controller controls the fuel injection
multiple engine output curves and selecting proper to obtain the selected engine output curve and
matching points. reduces excessive fuel consumption.
PC2000-8 17
1) Control method in each mode

q As the working modes, 2 modes of P and E
(with the E mode adjustment function) are set.
Select either working mode with the working
mode selector switch on the machine monitor.
q P mode and E mode (E0, E1)

(Including maximum pump absorption horsepower in each mode and the fan pump absorption horse-
power at maximum fan speed)
Mode Matching point

All modes During travel
728 kW/1800 rpm
During work {976 HP/1800 rpm}
(Heavy lift ON)
P
During work 699 kW/1800 rpm [721 kW/1800 rpm]
(Heavy lift OFF) {937 HP/1800 rpm} [966 HP/1800 rpm]
691 kW/1700 rpm [706 kW/1700 rpm]
E0 During work
{927 HP/1700 rpm} [947 HP/1700 rpm]
E
610 kW/1700 rpm [632 kW/1700 rpm]
E1 During work
{818 HP/1700 rpm} [848 HP/1700 rpm]
[ ]: 55°C spec.
q If the work equipment pump load increases 2) E mode adjustment function

and the pressure rises, the engine speed q The matching point in control of engine speed
decreases. At this time, pump delivery (Q) is (N) and engine torque (T) in the E mode can
decreased to control engine speed (N) to a be adjusted by operating the machine monitor.
speed near the rated output point. q The matching point can be set to 2 levels of E0
If the pressure lowers reversely, pump delivery and E1. In E1, the fuel efficiency is higher than
(Q) is increased to control the engine speed to in E0 but the production in unit time is lower.
the rated output point. q In the E mode (E1), the engine speed and
The engine speed is kept near the rated output engine output are lowered and fuel efficiency is
point by repeating the above controls. higher in the P mode and E mode (E0). The
q The engine speed and engine torque are so production in unit time is lower, however.
matched that the maximum output will be
obtained for boom raising operation, digging
operation, etc. which need larger output. For
the other operations which do not need the
maximum output, the engine output is lowered
to decrease the fuel consumption.
q In the P mode and the E mode (E0), CO is
canceled so that delivery (Q) at high pressure
will be larger than in the E mode (E1).
18 PC2000-8
Auto-deceleration function
Function q While the auto-low idle setting is ON, if all the

q If all the control levers are set in neutral when control levers are set in neutral when waiting
waiting for a dump truck or a next work, the for a dump truck or a next work, the engine
engine speed is decreased to the medium speed is decreased to the medium automati-
speed automatically to reduce fuel consump- cally. If the levers are kept in neutral for 30 sec-
tion and noise. onds, the engine speed is decreased to the low
speed automatically to reduce fuel consump-
tion and noise further.
q If any lever is operated, the engine speed
increases instantaneously to the set speed.
PC2000-8 19
Operation
1) While auto-deceleration switch is ON
(with auto-low idle setting OFF)
When all levers are set in neutral
q While the engine is running at a speed above
the deceleration speed (approx. 1,400 rpm), if
all the control levers are set in neutral, the
engine speed decreases instantaneously to
the 1st deceleration speed which is about 100
rpm lower than the set speed.
q If this condition is kept for 4 seconds, the
engine speed decreases to the 2nd decelera-
tion speed (approx. 1,400 rpm) and then it is
kept at that speed until a lever is operated.
When any lever is operated

q While the engine speed is kept at the 2nd
deceleration speed, if any control lever is oper-
ated, the engine speed increases instanta-
neously to the speed set with the fuel control
dial.
20 PC2000-8
2) While auto-deceleration switch is ON

(with auto-low idle setting ON)
When all levers are set in neutral
q While the engine is running at a speed above
the deceleration speed (approx. 1,400 rpm), if
all the control levers are set in neutral, the
engine speed decreases instantaneously to
the 1st deceleration speed which is about 100
rpm lower than the set speed.
engine speed decreases to the 2nd decelera-
tion speed (approx. 1,400 rpm).
engine speed decreases to the low idle speed
(approx. 825 rpm) and then it is kept at that
speed until a lever is operated.
When any lever is operated

q While the engine speed is kept at the 2nd
deceleration speed or low idle speed, if any
control lever is operated, the engine speed
increases instantaneously to the speed set
with the fuel control dial.
PC2000-8 21
Electronic OLSS function
Function
The electronic OLSS system, which replaced the
TVC valve, CO valve and NC valve of the former
hydraulic OLSS system, converts the pump dis-
charge pressure and J/S differential pressure into
electric signals with sensors. The controller per-
forms NC control calculation, PC characteristic con-
trol calculation and CO control calculation and
controls the variable swash plate control EPC to
control the pump swash plate.
22 PC2000-8
PC2000-8 23
1) NC control function
q If the operation stroke is increased, the carry-
over flow is decreased (See Fig. 1) and the out-
put pressure difference of the jet sensor (Pt –
Pd) is decreased (See Fig. 2).
q The differential pressure (Pt – Pd) is applied to
the differential pressure sensor and a voltage
is output. The relationship between the input
and output signals is shown in Fig. 3. If the out-
put pressure difference (Pt – Pd) is decreased,
the output voltage is increased.
q The output voltage of the differential pressure
sensor is input to the controller.
q The pump swash plate capacity is set accord-
ing to Fig. 4 and the controller supplies a cur-
rent to the pump EPC valve according to the
characteristics in Fig. 5.
q Since output pressure (Pi) of the EPC is
increased, the pump delivery is increased.
24 PC2000-8
2) PC characteristic control function 5) Emergency pump drive function

q The absorption torque of each pump is set with q This function is used when the machine has a
the engine and pump compound function and trouble (when user mode E07 occurs). If the
the pump capacity is calculated according to emergency pump drive switch (1) is turned
the characteristics in Fig. 6. “ON”, the pump capacity is set constant.
If the load on the machine increases and the pump
pressure rises, the pump capacity is decreased and
the pump absorption torque on the whole machine
is controlled constant.
3) Cut-off control function (Only when E1 is

set in E mode)
q If the load increases and pump discharge pres-
sure (P) rises to near the relief pressure during
work, the pump controller decreases the pump
delivery to decrease the relief loss.
4) Cut-off reset function

q The cut-off reset function means the function of
stopping the cut-off function and secures the
pump delivery near the relief pressure to pre-
vent the speed from lowering.
q Each switch and cut-off function
The cut-off function is reset in the P mode and
E mode (when E0 is set).
Switch Travel lever Heavy lift

Function ON OFF ON OFF
Cut-off function Reset Used Reset Used
PC2000-8 25
Heavy lift function
Outline
q This function increases the boom lifting power
by approx. 10%.
q It can be actuated only when the boom RAISE
is being actuated independently. If the arm IN
or bucket CURL are operated at the same
time, the heavy-lift function is automatically
canceled.
q Heavy lift function and Cut-off cancel function
will act at the same time.
26 PC2000-8
Operation
Lever operation Heavy-lift Main relief CO control
Boom lifting
Heavy-lift switch Arm IN or solenoid valve set P and
Boom RAISE E1 mode force
bucket CURL valve pressure E0 mode
29.4 MPa
OFF Operated — De-energized Canceled Actuated Normal
{300 kg/cm2}
32.9 MPa
Neutral Energized Canceled 10% up
{335 kg/cm2}
ON Operated If the arm IN or bucket CURL is operated during boom
RAISE operations, this function is automatically can-
Operated Normal
celed, and the condition becomes the same as when
the switch is turned OFF.
a Heavy-lift solenoid valve

For details of the structure and function, see “Solenoid valve”.
a Main relief valve
For details of the structure and function, see “L.H. 5-spool control valve”.
PC2000-8 27
2-stage boom pushing force selector function
Outline
q This function switches the pushing force of the
boom. It is aimed to provide both increased
digging efficiency by reducing the digging
resistance of the boom, and increased ease of
operation by increasing the thrusting force for
excavation, digging square holes, carrying out
twist turns, or escaping from soft ground.
28 PC2000-8
Operation
q This function acts to change the set pressure of the safety valve at the boom cylinder end of the L1 and
L2 control valve boom Lo in 2 ways: to low pressure (12.3 MPa {125 kg/cm2}) and high pressure (27.9
MPa {285 kg/cm2}.
Machine push-
Machine push- Safety valve set
Mode up solenoid Effect
up switch pressure
valve
By reducing the boom pushing force, it
is made easier for the boom to escape
Boom pushing automatically in the RAISE direction and
12.3 MPa
force Energized to reduce the number of times that the
{125 kg/cm2}
(low mode) boom is operated. At the same time it
also makes the digging operation
smoother.
By increasing the thrust force for boom

Boom pushing LOWER, the ease of operation is
27.9 MPa
force De-energized improved for excavation, digging square
{285 kg/cm2}
(high mode) holes, carrying out twist turns, or escap-
ing from soft ground.
a Machine push-up solenoid valve

For details of the structure and function, see “Solenoid valve”.
a Boom safety valve
For details of the structure and function, see “L1 and L2 control valve”.
PC2000-8 29
Swing control function
1. Swing lock, swing holding brake function

q The swing lock (manual) can be locked at any
desired position, and the swing holding brake
(automatic) is interconnected with the swing,
so they prevent any hydraulic drift after the
swing is stopped.
q The swing holding brake and ladder are linked
together. While the ladder is lowered and not in
the retraction position, the swing lock is
applied to prevent breakage of the ladder and
secure safety when the operator climb up and
down the ladder.
While the ladder is lowered, the ladder lower
warning lamp in the cab lights up.
a Swing brake solenoid valve
For details of the structure and function, see
“Solenoid valve”.
a Swing motor
For details of the structure and function, see
“Swing motor”.
30 PC2000-8
Actuation
Swing lock Swing lock Swing brake
Mode Actuation
switch monitor solenoid valve
When swing and work equipment levers are placed
at neutral, swing brake is applied after approx. 12
sec; when any swing or work equipment lever is
operated, brake is canceled and swing can be oper-
ated freely.
Swing holding See diagram

OFF OFF
brake on right
Swing lock is actuated and swing is held in position.

Swing brake ON ON De-energized Even when swing lever is operated, swing lock is not
canceled and swing does not run.
Operation of swing holding brake release switch

q If any abnormality should occur in the control-
ler, and the swing holding brake is not actuated
normally and the swing cannot be operated,
the swing holding brake release switch (1) can
be operated to cancel the swing lock and allow
the swing to be operated.
a Even when the swing holding brake release
switch is turned ON, the swing lock switch
stays ON and the swing brake is not canceled.
a When the swing brake is canceled, the swing
has only a hydraulic brake operated by the
safety valve, so if the swing is stopped on a
slope, there may be hydraulic drift.
a Even if the swing holding brake release switch
is turned ON, the swing brake is not reset
unless the ladders is in the retraction position.
Swing hold-
ing brake ON OFF
release (when controller is (when controller is
switch abnormal) normal)
Swing lock ON — OFF — ON — OFF —
switch
position
position
Storing
Storing
Lower
Lower
Ladder — — — —
Swing Swing Swing Swing

Swing brake lock lock lock lock
applied canceled applied canceled
PC2000-8 31
Engine automatic warming-up, overheat prevention function, turbo protect function, split
injection function
Function
q If the coolant temperature is low, this automati-
cally raises the engine speed to warm up the
engine after it is started. In addition, if the cool-
ant temperature rises too high during opera-
tions, it reduces the load of the pump to
prevent overheating.
q To protect the turbocharger bearing during cold
weather, the engine speed is kept below the
fixed speed when the engine is started. In
addition, to improve the starting ability, a small
amount of fuel is injected two or more times
before the main injection.
32 PC2000-8
1. Engine automatic warming-up function

q After the engine is started, if the engine coolant temperature is low, the engine speed is automatically
raised to warm up the engine.
2. Engine overheat prevention function

q This function protects the engine by lowering the pump load and engine speed to prevent overheating
when the engine coolant temperature has risen too high.
q This system is actuated at 95°C and above.
Operating condition Operation/Remedy Resetting condition
Coolant temperature: Below 105°C
⇒ ⇒
Work mode: Any mode Fuel control dial: Return to low idle posi-
Coolant temperature: Engine speed: Low idle tion once.
Above 105°C Monitor alarm lamp: Lights up • Under above condition, controller is
Alarm buzzer: Sounds set to condition before operation of
function. (Manual reset)

Work mode: Any mode
⇒ ⇒
Engine speed: Keep as is. Coolant temperature: Below 102°C
Coolant temperature: Monitor alarm lamp: Lights up • Under above condition, controller is
Above 102°C Alarm buzzser: Does not sound set to condition before operation of
Lower pump delivery. function. (Automatic reset)

Work mode: Any mode Coolant temperature: below 100°C and
⇒ ⇒
Hydraulic oil temperature: Engine speed: Keep as is. hydraulic oil temperature: below 95°C
Above 95°C or Monitor alarm lamp: Does not light • Under above condition, controller is
Coolant temperature: Alarm buzzser: Does not sound set to condition before operation of
Above 100°C Lower pump delivery. function. (Automatic reset)

Work mode: Travel Coolant temperature below 95°C and
Hydraulic oil or coolant
temperature:
Above 95°C
⇒ Engine speed: Keep as is.
Monitor alarm lamp: Does not light
Alarm buzzser: Does not sound
⇒ hydraulic oil temperature below 95°C
• Under above condition, controller is
set to condition before operation of
Lower travel speed. function. (Automatic reset)
PC2000-8 33
3. Turbo protection function

q Function to protect turbocharger bearing dur-
ing cold weather by keeping engine speed
below fixed speed when engine is started.
Actuation condition
Engine coolant Turbo protect time
temperature (sec)
More than +10°C 0
Gradually changes
+10°C to –10°C
between 0 and 5
Less than –10°C 5
Engine speed: 1000 rpm
q Even if the fuel control dial is operated during the

above time, the engine speed will not change.
After the set time passes, the operation moves to
the automatic warming up function.
4. Split injection function

q To improve the ease of starting in cold weather,
a small amount of fuel is injected two or more
times within the set time after calculating in the
table below before starting the main injection.
As a result, the lower idle speed during this
time becomes slightly higher.
Actuation condition
Coolant temperature Split injection time (sec)
More than 20°C 0
20°C to –30°C 0 – 15
Less than –30°C 15
34 PC2000-8
Boom shockless control function

This function improves safety by preventing spillage of the load from the bucket and by reducing the shock
when the boom is stopped, thereby reducing operator fatigue.
Actuation
Boom shockless Cancel solenoid Boom shockless
Remarks
switch valve control
ON
De-energized ON Suitable for normal operations
(Contacts open)
OFF
Energized Canceled Suitable for compacting or skeleton work
(Contacts closed)
q If the boom is raised, the pilot pressure (A) q In this condition, if the boom RAISE operation
from the PPC valve is generated in line (A). is stopped, the spool of the control valve
When this happens, the pressure in line (A) moves in the opposite direction to the arrow
passes through check valve (2) and pushes and drains the oil from line (A). However, the
the spool of the control valve in the direction of action of check valve (2) means that the oil
the arrow. The pilot oil at the left end of the must pass through orifice (1). As a result, the
spool passes through line (B) and the PPC spool returns slowly to the neutral position to
valve, and returns to the tank. However, when prevent any shock.
this happens, check valve (4) is being pushed
open by the pressure in line (A), so it also
allows the oil to pass in the opposite direction.
For this reason, the boom can be raised with-
out any delay in response.
PC2000-8 35
Straight travel function

Outline
q If the travel system and boom, arm, bucket or
swing system are operated simultaneously,
some of the oil flowing into the right or left
travel circuits is delivered to the boom, arm,
bucket or swing circuit.
In the travel circuit, the oil in which is divided,
less oil is supplied to the travel motor than in
the travel circuit, the oil in which is not divided.
As a result, the pressure in the former circuit
lowers and the machine deviates.
To prevent this, the straight travel PPC cut-off
valve sets the valves L1 and R2 for the work
equipment system and valves L2 and R1 for
the travel system by setting the spools of those
valves in neutral.
Operation
When boom, arm, bucket or swing system is
operated and travel system is not operated
q The straight travel valve solenoid valve does
not output oil and the straight travel valve spool
is in neutral. The outputs from the arm PPC
lever, boom PPC lever, bucket PPC lever and
right and left travel PPC levers are input to
valves L1, L2, R1 and R2. Accordingly, the
travel spool of valve L1, bucket, boom and arm
spools of valve L2, travel spool of valve R1,
and bucket, boom and arm spools of valve R2
are operated.
36 PC2000-8
Operation
When travel system and boom, arm, bucket or
swing system are operated
q The output from the straight travel valve sole-
noid valve changes the spools of both straight
travel valves CV1 and CV2, and then the out-
puts from the PPC levers of the arm, boom,
bucket and both travel systems are cut off.
Accordingly, valves L2 and R2 are used for the
operations of the left travel and right travel sys-
tems respectively, and valves L1 and R1 are
used for the operations of the systems other
than the travel system.
Even if the work equipment is operated under
this condition, the oil flow to the right and left
travel systems does not change and the
machine travels straight.
PC2000-8 37
Compound operation of swing system and arm

or bucket system
q When the arm system or bucket system and
swing system are operated simultaneously, the
swing priority PPC cut-off valve cuts the PPC
pressure on the arm and bucket spools of control
valve R1. Accordingly, the oil is supplied to the
swing system first to keep the swing operation
performance during the compound operation.
Operation
q If the swing PPC pressure exceeds 8 kg/cm2 and
the arm or bucket PPC pressure exceeds 5 kg/
cm2, the controller energizes the swing priority
solenoid valve, which outputs oil of 30 kg/cm2.
The output hydraulic signal operates the swing
priority PPC cut-off valve spool to cut off the
arm and bucket PPC pressure applied to con-
trol valve R1.
38 PC2000-8
Compound operation of swing system and

boom raise system
q When the boom raise system and swing sys-
tem are operated simultaneously, the throttle
valve in the boom parallel circuit is operated to
supply the oil to the swing system first to keep
the swing operation performance during the
compound operation.
Operation
q If the swing PPC pressure exceeds 8 kg/cm2 and
the boom raise PPC pressure exceeds 5 kg/cm2,
the controller energizes the boom throttle sole-
noid valve, which outputs oil of 30 kg/cm2.
The high-pressure selector valve outputs the
main pump pressure according to the output
hydraulic signal to operate the boom throttle
valve of control valve R1, which throttles the
boom raise circuit. Accordingly, the oil in valve
R1 flows to the swing spool to maintain the
swing operation.
PC2000-8 39
Compound operation compensation function
Outline Operation of arm throttle valve “for valve L1”

q When the arm system and boom raise system q When the arm system and boom raise system
or bucket system are operated simultaneously, or bucket system are operated simultaneously,
the oil flow to the boom or bucket circuit is the controller energizes the arm throttle sole-
secured by the throttle valve in the arm circuit noid valve “for valve L1”, which outputs oil of
to maintain the compound operation perfor- 30 kg/cm2.
mance. The high-pressure selector valve outputs the
hydraulic pump pressure to lock the pilot check
valve of the arm throttle valve of control valve
L1, according to the output hydraulic signal.
q Under this condition, since the oil passage in
control valve L1 is a parallel circuit, the flow
into the arm circuit is throttled and the drive
pressure for the boom raise or bucket system
is increased.
Accordingly, the boom raise operation or
bucket operation is maintained.
40 PC2000-8
Operation of arm throttle valve “for valve R2”

q When the arm system and boom raise system
are operated simultaneously, the controller
energizes the arm throttle solenoid valve “for
valve R2”, which outputs oil of 30 kg/cm2.
The high-pressure selector valve outputs the
hydraulic pump pressure to lock the pilot check
valve of the arm throttle valve of control valve
R2, according to the output hydraulic signal.
q Under this condition, since the oil passage in
control valve R2 is a parallel circuit, the flow
into the arm circuit is throttled and the drive
pressure for the boom raise system is
increased.
Accordingly, the boom raise operation is main-
tained.
PC2000-8 41
Variable back pressure compensation

function
A back pressure compensation valve is required to
increase the back pressure in the control valve return
circuit and prevent cavitation in the swing and travel
motors. This valve is a constant resistance in the
hydraulic circuit, which causes a hydraulic loss during
operations other than swing and travel, however. To
eliminate this hydraulic loss, a variable back pressure
compensation valve is employed. This valve is con-
trolled electronically by the controller so that it will
generate back pressure only when necessary (during
travel or swing operation).
Explanation of operation of variable back pressure valve

During swing or travel operation:The solenoid valve is turned OFF and the poppet is pressed by the spring
force as ever and back pressure is generated in the main valve return circuit.
During other operations: The solenoid valve is turned ON and the poppet moves in the direction of
the arrow to cancel the spring force. As a result, the resistance in the con-
trol valve return circuit is decreased and the back pressure is decreased
accordingly.
42 PC2000-8
Function
q During the travel or swing operation, back
pressure is generated in the drain circuit to
prevent cavitation.
q During the operations other than the travel and
swing operations, the back pressure in the
drain circuit is decreased to reduce the loss.
Operation
1. During travel or swing operation
q No oil is supplied from solenoid valve (4) and
no pressure is generated in pilot circuit (a).
q The oil from the control valve acts on left end
(Ab) of valve (1) and generates back pressure
in drain circuit (b) with springs (2) and (3).
PC2000-8 43
2. During operations other than 1

q The oil from solenoid valve (4) flows in pilot cir-
cuit (a) and acts on left ring surface (Aa) of
valve (1) to push back springs (2) and (3).
q Since valve (1) is moved to the right, the oil
from the control valve generates less back
pressure in drain circuit (b).
Unit: mm
Criteria
No. Check item Free length × Remedy
Outside Installed length Installed load Free length Installed load
diameter
1372. 8 N 1098. 3 N
2 Spring (2) 187.48 × 38.5 130 — If damaged or
{140 kg} {112 kg}
deformed,
3 Spring (3) 116.18 × 19.5 90 —
{23.6 kg} {18.9 kg}
44 PC2000-8
Hydraulic fan control function

1) Hydraulic fan speed control function
q The fan speed on the radiator side is controlled
according to the engine speed and coolant
temperature.
q The fan speed on the oil cooler side is con-
trolled according to the engine speed and
hydraulic oil temperature.
q When the coolant temperature and hydraulic oil
temperature are low, the fan speed is lowered to
decrease the noise and fuel consumption.
PC2000-8 45
2) Engine output control function

q The pump controller calculates the horsepower
consumed by the fans and controls engine out-
put curve (A) according to the fan speed to
decrease the fuel consumption.
46 PC2000-8
Fan reverse function

q The cooling devices can be cleaned easily by
rotating the fan in reverse.
q The heat in the power container can be dis-
charged before servicing by rotating the fan in
reverse.
q Upon receiving the fan reverse signal from the
machine monitor, the pump controller drives
the reverse EPC valve of the fan motor to
change the fan reverse valve. By this opera-
tion, the fan rotation direction is reversed.
q The fans on the radiator side and oil cooler
side cannot be reversed separately.
q The fan speed in reverse direction is controlled
by only the engine speed, regardless of the cool-
ant temperature and hydraulic oil temperature.
PC2000-8 47
Pump controller
Pump controller 1
48 PC2000-8
Input and output signals

CN1 CN2
Input/ Input/
Output Output
1 O/C FAN pump pressure sensor Input 1 NC Output
2 VL1/P1R J/S differential pressure sensor Input 2 NC Input
3 VL1/P1R pump pressure sensor Input 3 NC Input
4 GND_SIG_D — 4 232C_R x D Input
5 NC Input 5 Fuel level switch (Middle) Input
6 NC Input 6 NC Input
7 RAD_FAN pump pressure sensor Input 7 Machine select 4 Input
8 VR1/P1F J/S differential pressure sensor Input 8 NC Output
9 VR1/P1F pump pressure sensor Input 9 NC Output
10 GND_SIG_D — 10 NC Input
11 NC Input 11 NC Output
12 NC Input 12 CAN shield —
13 VL2/P2R J/S differential pressure sensor Input 13 Machine select 5 Input
14 VL2/P2R pump pressure sensor Input 14 232C_T x D Output
15 NC Input 15 Fuel level switch (H1) Input
16 NC Output 16 NC Input
17 Start switch (C) Input 17 Machine select 3 Input
18 Auto grease manual select switch Input 18 NC Output
19 VR2/P2F J/S differential pressure sensor Input 19 Manual grease operation lamp Output
20 VR2/P2F pump pressure sensor Input 20 NC Input
21 GND_SIG_A — Input/
21 S_NET
22 PWR_OUT_5V_0 Output Output
23 Key switch (ACC) Input Input/
22 COMM_CAN_L_0
Output
24 NC Input
Input/
23 COMM_CAN_L_1
Output
24 PWR_CTR_EXT Input
25 NC Input
26 NC Input
27 Machine select 2 Input
28 NC Input
29 GND_SIG_P —
30 NC Input
31 GND (S_NET_GND) —
Input/
32 COMM_CAN_H_0
Output
Input/
33 COMM_CAN_H_1
Output
34 GND (232C_GND) —
35 Auto grease low level switch Input
36 Fuel level switch (Low) Input
38 NC Input
39 GND_SIG_P —
40 NC Input
PC2000-8 49
CN3
Input/
Pin No. Signal name
Output
1 PWR_IN_BATT Input
2 PWR_IN_BRY Input
3 GND_ACT Input
4 Battery relay hold Output
5 RAD FAN EPC solenoid Output
6 P1F pump EPC solenoid Output
7 Auto grease solenoid Output
8 Auto grease caution LED Output
9 NC Input
10 NC Input
11 PWR_IN_BATT Input
12 PWR_IN_BRY Input
13 GND_ACT Input
14 PWR_CTR_KEY Input
15 O/C FAN EPC solenoid Output
16 P1R pump EPC solenoid Output
17 NC Output
18 FAN reverse caution LED Output
19 NC Input
20 NC Input
C21 GND_PWR Input
22 PWR_CTR_BRY Input
23 GND_ACT Input
25 RAD FAN reverse solenoid Output
26 P2F pump EPC solenoid Output
27 NC Output
28 NC Output
29 NC Input
30 NC Input
31 GND_PWR Input
32 GND_PWR Input
33 GND_PWR Input
34 PWR_OUT_5V_0 Output
35 O/C FAN reverse solenoid Output
36 P2R pump EPC solenoid Output
37 NC Output
38 NC Output
39 NC Input
40 NC Input
50 PC2000-8
Pump controller 2
PC2000-8 51

CN1 CN2
Input/ Input/
Output Output
1 Swing right PPC pressure sensor Input 1 NC Output
2 Arm dump PPC pressure sensor Input 2 Swing redundancy switch Input
3 Auto grease pressure sensor Input 3 NC Input
4 GND_SIG_D — 4 232C_R x D Input
6 Upper wiper proximity switch Input 6 NC Input
7 Swing left PPC pressure sensor Input 7 Machine select 4 Input
8 Arm digging PPC pressure sensor Input 8 Step light relay output Output
9 Hydraulic oil temperature sensor Input 9 NC Output
10 GND_SIG_D — 10 NC Input
11 Step light switch Input 11 NC Output
12 NC Input 12 CAN shield —
13 Bucket dump PPC pressure sensor Input 13 Machine select 5 Input
14 Boom down PPC pressure sensor Input 14 232C T x D Output
17 Start switch (C) Input 17 Machine select 3 Input
18 Horn switch Input 18 NC Output
19 Bucket digging PPC pressure sensor Input 19 NC Output
20 Boom up PPC pressure sensor Input 20 NC Input
21 GND_SIG_A — Input/
21 S_NET
22 PWR_OUT_5V_0 Output Output
23 Key switch (ACC) Input Input/
22 COMM_CAN_L_0
Output
24 Ladder down signal Input
Input/
23 COMM_CAN_L_1
Output
24 PWR_CTR_EXT Input
25 NC Input
26 NC Input
28 NC Input
29 GND_SIG_P —
30 NC Input
31 GND (S_NET_GND) —
Input/
32 COMM CAN_H_0
Output
Input/
33 COMM CAN_H_1
Output
34 GND (232C_GND) —
35 Service PPC pressure switch Input
36 NC Input
38 Swing lock switch Input
39 GND_SIG_P —
40 NC Input
52 PC2000-8
CN3
Input/
Pin No. Signal name
Output
1 PWR_IN_BATT Input
2 PWR_IN_BRY Input
3 GND_ACT Input
4 NC Output
5 Travel straight valve solenoid Output
6 Upper wiper lo output Output
7 Swing parking brake valve solenoid Output
8 Flash light relay output Output
9 NC Input
10 Upper wiper limit switch Input
11 PWR_IN_BATT Input
12 PWR_IN_BRY Input
13 GND_ACT Input
15 Two stage relief valve solenoid Output
16 Upper wiper lo brake output Output
17 Window washer output Output
18 Travel alarm output Output
19 NC Input
20 Lower wiper limit switch Input
21 GND_PWR Input
22 PWR_IN_BRY Input
23 GND_ACT Input
25 Bucket Hi cancel valve solenoid Output
26 Lower wiper lo output Output
27 Arm restriction L valve solenoid Output
28 Variable back pressure valve solenoid Output
29 Travel left PPC pressure switch Input
30 NC Input
31 GND_PWR Input
32 GND_PWR Input
33 GND_PWR Input
34 PWR_OUT_5V_0 Output
35 Boom restriction valve solenoid Output
36 Lower wiper lo brake output Output
37 Arm restriction R valve solenoid Output
38 Swing priority valve solenoid Output
39 Travel right PPC pressure switch Input
40 NC Input
PC2000-8 53
Pump emergency drive redundant resistor
1. Resistor Function
2. Connector q When the pump emergency drive switch is
turned ON, a proper current is supplied to the
Specification pump EPC through this resistor.
Resistance: 30 z
54 PC2000-8
Monitor system 1
q The monitor system notifies the operator of

machine status. It monitors the condition of the
machine with the sensors mounted on various
parts of the machine, processes and immedi-
ately displays the obtained information on the
panel.
Contents displayed on the panel are largely
divided into the following.
1. Alarm when an abnormality occurs on the
machine
2. Machine condition (Temperature of cool-
ant and hydraulic oil, fuel level, etc.)
q Also, the machine monitor is provided with var-
ious mode selector switches that function as
the operation unit of the machine control sys-
tem.
PC2000-8 55
Machine monitor 1
Outline
q The machine monitor has the functions to dis-
play various items and the functions to select
modes and electric parts.
q The machine monitor has a CPU (Central Pro-
cessing Unit) in it to process, display, and out-
put the information.
q The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
56 PC2000-8
CN-CM01 CN-CM04
Input/ Input/
output output
1 Battery power (+24V constantly) Input 1 GND —
2 Battery power (+24V constantly) Input 2 DOS Output
3 Battery power GND — 3 GND —
4 Battery power GND — 4 Communication 232C Output
Input/ 5 Communication 232C Input
5 Wake-up
Output 6 NC(*) —
6 Relay output Output 7 NC(*) —
7 Chassis signal GND — 8 NC(*) —
8 Hydraulic oil temperature Input 9 NC(*) —
9 Fuel level Input 10 NC(*) —
10 Coolant temperature Input 11 NC(*) —
11 Charge amount Input 12 PWR OUT Output
12 Chassis analog signal GND — *: Never connect to NC or malfunctions or failures
13 Light switch Input will occur.
14 Key switch (ACC) Input
15 Key switch (C) Input CN-CM05
16 Preheating Input
Input/
17 Power out Output Pin No. Signal name
output
18 GND power —
Electric power supply for cam-
*: Never connect to NC or malfunctions or failures 1 Output
era
will occur.
2 Camera NTSC signal input 1 Input
CN-CM02 3 Camera NTSC signal input 2 Input
Input/ 4 Camera NTSC signal input 3 Input
Pin No. Signal name
output Electric power supply GND for
1 Engine oil pressure sensor Input 5 —
camera
2 Engine oil level sensor Input
6 Camera signal GND1 —
3 Coolant level sensor Input
7 Camera signal GND2 —
4 Air cleaner clogging sensor Input
5 Swing lock Input 8 Camera signal GND3 —
6 NC(*) Input
7 Chassis signal GND —
8 CAN terminating resistance —
Input/
9 CAN_H
Output
Input/
10 CAN_L
Output
Input/
11 NC(*)
Output
Input/
12 NC(*)
Output
*: Never connect to NC or malfunctions or failures
will occur.
PC2000-8 57
Monitor control, display portion 1
q AA (1/2): Ordinary work screen (1/2) q BB: Check before starting screen
q AA (2/2): Ordinary work screen (2/2) q CC: Maintenance interval caution screen
1. Engine coolant temperature monitor 16. Truck counter 1

2. Engine coolant temperature gauge 17. Truck counter 2
3. Hydraulic oil temperature monitor 18. ECO indicator
4. Hydraulic oil temperature gauge 19. PTO oil temperature monitor
5. Fuel level monitor 20. PTO oil temperature gauge
6. Fuel gauge 21. Engine oil temperature monitor
7. Wiper monitor 22. Engine oil temperature gauge
8. Swing lock monitor 23. Engine oil pressure monitor
9. Engine pre-heating monitor 24. Engine oil pressure gauge
10. Auto-greasing monitor 25. Radiator coolant level monitor
11. Engine stop monitor 26. Charge level monitor
12. Time/service meter 27. Engine oil pressure monitor
13. Auto-deceleration monitor 28. Engine oil level monitor
14. Working mode monitor 29. Air cleaner clogging monitor
15. Heavy lift monitor 30. Maintenance interval monitor
58 PC2000-8
Precautions on the machine monitor display

q The liquid crystal display panel may have black
spots (which do not light up) or bright spots
(which stay on).
Products having 10 or less black or bright
spots conform the product specification; such
the condition is quite normal.
q Battery voltage may suddenly drop at engine-
start due to ambient temperature or the condi-
tion of the battery. The machine monitor dis-
play may temporarily disappear if it happens; it
is quite normal.
q Continuous operation of the machine monitor
may display blue bright spots on the screen
having a black background; it is quite normal.
The screen normally displayed on the monitor
has a blue or white background. For this rea-
son, blue spots will not cause any problem
(since the liquid crystal lights up red, blue, and
green spots when displaying white).
PC2000-8 59
Monitor items and display
Symbol Display item Display method
Swing holding brake

Swing lock switch Display of symbol
release switch
OFF OFF OFF
Swing lock
ON OFF ON
OFF ON Flashes
ON ON Flashes
Preheater operates at low temperature and

Automatic preheating symbol keeps lighting up for up to about 30
seconds and then goes off after engine starts.
Preheating Time after setting Display of symbol

0 – 30 sec ON
Manual preheating
30 – 40 sec Flashes
After 40 sec OFF
Engine coolant
temperature
Hydraulic oil
temperature
Fuel level See gauge display on next page.
PTO oil
temperature
Engine oil
Pressure
60 PC2000-8
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Gauge display: 1/2

Gauge Range Temperature or volume Indicator Buzzer sound
A1 105 Red Q
A2 102 Red
Engine coolant A3 100 Off
temperature
(°C) A4 85 Off
A5 60 Off
A6 30 White
B1 103 Red
B2 100 Red
Hydraulic oil B3 97 Off
temperature
(°C) B4 85 Off
B5 40 Off
B6 20 White
C1 2,800 Off
C2 2,100 Off
C3 1,250 Off
Fuel level (l)
C4 700 Off
C5 500 Off
C6 250 Red
PC2000-8 61
Gauge display: 2/2

Gauge Range Temperature or volume Indicator Buzzer sound
D1 125 Red Q
D2 122 Red
PTO oil temperature D3 120 Off
(°C) D4 100 Off
D5 50 Off
D6 0 White
E1 125 Red
E2 122 Red
Engine oil temperature E3 120 Off
(°C) E4 100 Off
E5 50 Off
E6 0 White
F1 7 Off
F2 6 Off
Engine oil pressure F3 4 Off
(kg/cm2) F4 2 Off
F5 0.6 Off
F6 0.2 Red
62 PC2000-8
Checks before starting (all symbols light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic
oil temperature gauge and the hydraulic oil temperature monitor disappear and the following symbols are
displayed.
Check before starting While engine is While engine is

Symbol Display item
item stopped running
Lights up and buzzer

Engine oil pressure q —
sounds when abnormal.
Lights up when
Battery charge q —
abnormal.
Lights up when Lights up and buzzer

Radiator coolant level q abnormal. sounds when abnormal.
Lights up when
Engine oil level q abnormal.
—
Lights up when
Air cleaner clogging q —
abnormal.
Notice lamp (yellow)/Warning lamp (red).

Maintenance Lights up for only 30 seconds after starting
switch is turned ON.
Symbols appear in the order in which they occur

from the upper left. When symbols are displayed, if
the hydraulic oil temperature is high or low, only its
symbol is displayed.
Condition of hydraulic oil Color of symbol
Low temperature Black on white
(below B6 or equivalent) background
Normal (B6 – B2) No display
White on red
High temperature (above B2)
background
PC2000-8 63
Items other than work check items

Method of Condition for occurrence
Check Condition for
Caution Symbol notifying
component Item Sub item reset
operator
Connection of sensor Monitor analog input
Normal
Fuel level gauge display 1
While engine judgment
is stopped Abnormal
Fuel level gauge display 0
judgment
Change of Normal Same as while engine is Above fuel
Fuel level
Monitor symbol color While engine judgment stopped level gauge
reduction
(Blue o Red) is operated Abnormal display 1
judgment
Moving average of values
Filter time input at intervals of 500
msec is obtained.
Remarks
Connection of sensor Engine controller
Normal Temperature equivalent to
While engine judgment 102°C or below
is stopped Abnormal Temperature equivalent to
Change of
symbol color judgment 102°C or above
Engine (Blue o Red) Normal Same as while engine is As per logic
Engine
coolant When above While engine judgment running in engine
controller
overheat 105°C, buzzer is operated Abnormal controller
sounds inter- judgment
mittently.
As per logic in pump con-
Filter time
troller
Alarm is masked in 100
Remarks
sec after engine is started.
Connection of sensor Engine controller
Normal Temperature equivalent to
While engine judgment 102°C or below
Change of is stopped Abnormal Temperature equivalent to
symbol color judgment 102°C or above
Hydraulic (Blue o Red) Normal Same as while engine is As per logic
Pump
oil over- When above While engine judgment running in engine
controller
heat 105°C, buzzer is operated Abnormal controller
sounds inter- judgment
mittently.
Filter time
troller
Alarm is masked in 100
Remarks
sec after engine is started.
Connection of sensor Pump controller
Normal As per logic in pump con-
While engine judgment troller
is stopped Abnormal As per logic in pump con-
Auto- judgment troller
grease As per logic
Display of Normal As per logic in pump con-
system in pump con-
symbol While engine judgment troller
abnormal- troller
ity is operated Abnormal As per logic in pump con-
judgment troller
Filter time
troller
Remarks Obtained by RTCDB2
64 PC2000-8
Method of Condition for occurrence

Check Condition for
Caution Symbol notifying
component Item Sub item reset
operator
Connection of sensor VHMS ON/OFF input
Normal
While engine judgment
is stopped Abnormal
Hydraulic judgment Other than
Display of
oil level Normal When sensor contact is conditions
symbol
reduction While engine judgment closed shown at left
is operated Abnormal When sensor contact is
judgment open
Filter time 3 sec
Remarks
Connection of sensor VHMS ON/OFF input
Normal When sensor contact is
While engine judgment closed
is stopped Abnormal When sensor contact is
judgment open
Normal
Hydraulic Other than
Display of While engine judgment
oil filter conditions
symbol is operated Abnormal
clogging shown at left
judgment
Filter time 10 sec
Detected only when
hydraulic oil temperature is
Remarks
above 25°C
Obtained by RPC
Check Screen page

before 1/2 2/2
starting Gauge Monitor Caution Gauge Monitor Caution
Engine coolant temperature q q q
Hydraulic oil temperature q q a q
Fuel level q q q
PTO oil temperature q q q
Engine oil temperature q q q a
Engine oil pressure q q q q
Charge level q q q
Radiator coolant level q q q
Engine oil level q q q
Air cleaner clogging q q q
Auto-grease system abnormality q q
Hydraulic oil level q q
Hydraulic oil filter clogging q q
Maintenance q q
a: If another caution is displayed, these items are displayed only when abnormal.
PC2000-8 65
Display
Symbol Display item Display range Display method
category
Windshield wiper Setting condition is displayed.
Working mode P, E Setting mode is displayed.
Operating condition is displayed.

(Auto-deceleration or auto-low
Auto-deceleration Operation Reset
idle is selected on user mode
menu)
Heavy lift ON OFF Setting condition is displayed.
Monitor Operating condition is displayed.

(Auto-deceleration or auto-low
Auto-low idle Operation Reset
idle is selected on user mode
menu)
Engine stop Displayed when engine stop is

Stop Operation
indicator judged
Display of auto- Displayed when grease level is

Alarm Normal
grease low level low
Auto-greasing Operation Stop Displayed during auto-greasing
Truck Truck counter 1

0 – 99 Number of counts
counter Truck counter 2
Green: Average of load in 1 minute is

ECO Work load is light – medium. displayed in 10 levels.
ECO indicator
indicator Orange: (Not displayed if ECO display is
Work load is heavy. turned “OFF” in service menu.)
Operating time is displayed.

Service Service meter
While service meter is operating (If F4 is pressed, clock is dis-
meter indicator
played instead.)
Clock is displayed.
12-hour display
Clock Clock (If F4 is pressed, service meter
24-hour display is displayed instead.)
66 PC2000-8
Switches 1
1. Buzzer cancel switch Buzzer cancel switch

2. Auto-deceleration switch/auto low idle switch Pressing this switch when the alarm buzzer is mak-
3. Guidance icon ing sound stops the alarm buzzer.
4. Function switch If a new abnormality is detected, the alarm buzzer
5. Working mode selector switch sounds.
6. Heavy lift switch Depending on the alarm buzzer type, it does not
7. Window washer switch stop even if you press the buzzer cancel switch.
8. Wiper switch
Auto-deceleration switch/auto low idle switch
This switch toggles the auto-deceleration or auto
low idle function on and off. When the working
mode is switched, it is automatically set to ON.
When it is set to ON, the auto-deceleration monitor
appears.
68 PC2000-8
Guidance icon and function switch

The function switches differ depending on the
screen display. Each guidance icon shows the func-
tion of the switch below it.
Switches with no guidance icon are disabled.
The functions shown by the guidance icons are as
shown in the table below.
Symbol Switch Item Function
F6 Enter Enters selected/set item.
F5 Return Returns to previous screen.
F4 Select service meter/clock Selects service meter and clock alternately.
F5 Select maintenance screen Selects maintenance screen.
F6 Select user mode screen Selects user mode screen.
Selects item on left side (Selects right end item after left
F3 Select item
end item).
Selects item on right side (Selects left end item after right
F4 Select item
end item).
Selects item on lower side (Selects top item after bottom
F3 Select item
item)/Resets holding of monitoring.
Selects item on upper side (Selects bottom item after top
F4 Select item
item)/Holds monitoring.
Selects page on lower side (Selects top page after bottom
F1 Select item
page).
Selects page on upper side (Selects bottom page after top
F2 Select item
page).
F1 Display No. 1 camera screen Selects No. 1 camera screen.
Display No. 1 and No. 2

F4 Displays No. 1 and No. 2 camera screens simultaneously.
camera screens
F1 Ordinary work screen select Selects (1/2) or (2/2) screen.
Returns selected item to default setting.

F2 Return to default setting
(Used for adjustment of screen.)
Starts operation. (Used to start measurement of split fuel
F1 Start
consumption on fuel consumption display screen.)
Stops operation. (Used to stop measurement of split fuel
F1 Stop
consumption on fuel consumption display screen.)
F1/F2 Clear Clears selected/displayed item
F1 Set Executes setting.
PC2000-8 69
Working mode selector switch Camera screen display function 1

Pressing working mode selector switch switches q For an optional-camera-equipped machine,
among working modes. pressing the F3 on the normal screen switches
Check the working mode on the working mode to the camera image.
monitor. q For a machine with no camera equipped, the
guidance icon for switching to the camera
screen does not appear; even if you press the
switch, the screen does not switch to the cam-
era image.
q Up to three cameras are mountable.
Window washer switch

While the switch is being pressed, window washer
liquid is sprayed out. There is a time delay before
the wiper starts.
Wiper switch
F1 : Displays the image of No. 1 camera full-screen.
Each time you press the wiper switch, the wiper F2 : Displays the image of No. 2 camera full-screen.
settings switch as follows. F3 : Displays the image of No. 3 camera full-screen.
OFF o INT o ON (upper, lower) o ON (UPPER) F4 : Displays the images of No. 1 and No. 2 cam-
o OFF o …. eras at the same time.
The wiper operation setting is confirmable on the F5 : Returns to the normal screen.
wiper monitor.
The relationship between the wiper setting and the q Even when the camera screen is displayed,
monitor display is shown in the table below. the working mode selector switch, heavy lift
switch, auto-deceleration switch, buzzer can-
Setting Display Wiper actuation status cel switch, wiper switch, and window washer
Stowing stopped or switch are enabled.
OFF None q Changing the working mode returns to the nor-
now stowing
mal screen.
q If an abnormality corresponding to an alarm
INT Intermittent actuation item with the camera screen displayed, the
alarm monitor appears on the upper left of the
screen. If it appears, return to the normal
screen with F5 to check the alarm display.
q If an abnormality corresponding to an error
ON Upper, lower wiper
(LOWER) continuous actuation item with the camera screen displayed, the
error monitor appears on the upper left of the
screen. If it appears, you must move the
machine to safe posture immediately and
ON Upper wiper make inspections.
(UPPER) continuous actuation q If you do not operate the lever at least 10 sec.
after the error monitor starts to blink, the
screen switches to the normal screen.
70 PC2000-8
Service meter/time selector function 1

q Pressing F4 on the normal screen when the
service meter is displayed in the top center of
the screen switches the display to the time,
and doing so when the time is displayed
switches the display to the service meter.
PC2000-8 71
Maintenance function 1 q If the remaining time on the maintenance table

q Pressing F5 on the normal screen switches to screen is less than 30 hours, the relevant items
the maintenance screen. are highlighted in yellow, and if 0 hours, they
are done in red.
q On the maintenance time reset screen, reset
the remaining time for the selected item to
return to the default.
F5 : Cancels the reset to return to the maintenance

table screen.
F6 : Resets the remaining time to return to the nor-
mal screen.
No operation at least 30 sec. : Returns to the nor-
mal screen.
q The table below shows the maintenance items

and replacement intervals. The time remaining
to maintenance is reduced as the machine is
F1 : Displays the next page.
operated.
Displays the top page when the last page is
displayed. Replacement interval
No. Item
F2 : Displays the previous page. (Hours)
Displays the last page when the top page is 01 Engine oil 500
displayed. 02 Engine oil filter 500
F3 : Selects (highlights) an item one down. 03 Fuel main filter 1000
F4 : Selects (highlights) an item one up. 41 Fuel prefilter 500
F5 : Returns to the normal screen. 04 Hydraulic filter 1000
F6 : Switches to the maintenance time reset screen. 05 Hydraulic tank breather 1000
No operation at least 30 sec. : Returns to the nor- 06 Corrosion resistor 1000
mal screen. 07 PTO case oil 1000
08 Final case oil 2000
09 Machinery case oil 1000
10 Hydraulic oil 5000
30 Hydraulic oil pilot filter 500
31 Hydraulic oil drain filter 500
— Oil cooler accumulator 4000
72 PC2000-8
q The content of the caution display differs accord-

ing to the remaining time. The relationship is as
shown in the table below.
Display Condition
Remaining time for mainte-
None nance for all items is more
than 30 hours.
There is one or more items
Notice display
with less than 30-hour
(black symbol displayed
remaining time for mainte-
on yellow background)
nance.
There is one or more items
Warning display
with less than 0-hour
(white symbol displayed
remaining time for mainte-
on red background)
nance.
q You can lock the maintenance time by a pass-

word to prevent it from carelessly being reset.
q The default password is “000000”.

a For information on changing the maintenance
pa ss wo rd , se e “M ai nte nan c e pas sw or d
change function” in the Testing and adjusting
section.
PC2000-8 73
User mode 1 Screen adjustment

q Pressing F6 on the normal screen enters the q Selecting the “Screen adjustment” from the user
user mode, switching to the user menu screen. menu and pressing F6 switches to the screen
q In user mode, you can specify items relating to adjustment screen.
the machine monitor and machine shown below. q From this menu, you can adjust the brightness,
Screen adjustment contrast, and luminance of the machine moni-
ECO display selection tor screen.
Time adjustment q When the light switch is in Night mode ON, the
Language setting night mode screen is adjustable.
Economy mode adjustment q When the light switch is in Daytime mode ON or
Auto-low idle setting OFF, the daytime mode screen is adjustable.
Truck counter correction/clearing
Hydraulic fan reverse setting
F2 : Returns all adjusted values to the defaults.

F3 : Decreases the value indicated by the indicator
F3 : Selects (highlights) an item one down.
one graduation left.
F4 : Selects (highlights) an item one up.
F4 : Increases the value indicated by the indicator
F5 : Returns to the normal screen.
one graduation right.
F6 : Switches to the setting screen for the selected
F5 : Cancels changes you made before confirming
item.
them with F6 to return to the menu screen.
No operation at least 30 sec. : Returns to the nor-
F6 : Confirms the changes and moves to the next
mal screen.
item.
(In user mode, no switch operation at least 30 sec.
returns to the previous screen.) q For a camera-equipped machine, the bright-
ness, contrast, and illuminance of the camera
screen are also adjustable.
q For a camera-equipped machine, selecting
Sc reen adjustme nt from the us er me nu
switches to the screen for selecting a screen
you want to adjust.
74 PC2000-8
F3 : Selects (highlights) an item one down. Clock adjustment

F4 : Selects (highlights) an item one up. q Selecting the “Clock adjustment” from the user
F5 : Cancels changes you made before confirming menu and pressing F6 switches to the clock
them with F6 to return to the menu screen. adjustment screen.
F6 : Moves to the setup items of the selected (high- q On this screen, you can change the setting of
lighted) item. the time displayed on the normal screen.
q The adjustment methods for the camera screen
and normal screen are the same.
q The background when adjusting the camera
screen is the No. 1 camera image.
1) Time setting
Set the clock time. If the time setting item
is not highlighted, press F6 to highlight it.
The time display part is highlighted.

F3 : Selects (highlights) an item one down. F3 : Advances the clock one hour.
F4 : Selects (highlights) an item one up. F4 : Sets the clock back one hour.
F5 : Cancels changes you made before confirming F5 : Cancels changes you made before
them with F6 to return to the menu screen. confirming them with F6 to return to
F6 : Moves to the setup items of the selected (high- the user menu.
lighted) item. F6 : Confirms the changes and moves to
minute setting.
The minute display part is highlighted.

F3 : Advances the clock one min.
F4 : Set the clock back one min.
F5 : Cancels changes you made before
confirming them with F6 to return to
the use menu.
F6 : Confirms the changes and moves to
the 12/24 display mode.
2) 12/24 display mode

Specify time display to 12-hour display
(AM/PM) or 24-hour display. If the item of
12/24 display mode is not highlighted,
press F6 to highlight it.
F3 : Moves to the item one right.
F4 : Moves to the item one left.
F5 : Cancels the changes to return to the
user menu.
F6 : Confirms the changes and moves to
summer time.
PC2000-8 75
3) Summer time Economy mode adjustment

Selecting ON for this sets the time forward q Selecting the “Economy mode adjustment” from
one hour. Setting OFF returns to the ordi- the user menu and pressing F6 switches to the
nary time. Economy mode setting screen.
F3 : Moves to the item one right. q From this menu, you can adjust engine output
F4 : Moves to the item one left. to improve fuel consumption in E mode.
F5 : Cancels changes you made before q The fuel consumption level is specified to one
confirming them with F6 to return to of two levels from E0 to E1. The larger the
the user menu screen. value, the better the fuel consumption, but the
F6 : Confirms the changes and moves to smaller the work rate.
the time setting.
a Summer time (daylight saving time) is

a system to lead a life according to
the one-hour advanced time in order
to make efficient use of daylight time.
Language setting
q Selecting the “Language” from the user menu
screen and pressing F6 switches to the lan-
guage setting screen.
q From this menu, you can change the language
to be displayed on the monitor. Available lan-
guages are as follows.
English, Japanese, Chinese, French, Spanish, F3 : Selects (highlights) an item one down.
Portuguese, German, Russian, and Indone- F4 : Selects (highlights) an item one up.
sian F5 : Cancels the changes to return to the user menu.
F6 : Confirms the changes to return to the user menu.
F3 : Selects (highlights) an item one down.

F4 : Selects (highlights) an item one up.
F5 : Cancels the changes to return to the user menu.
F6 : Confirms the changes to return to the user menu.
76 PC2000-8
ECO display selection
q Select “Select ECO display” on the user menu

screen and press F6, and the screen changes
to the Select ECO display screen.
q Press F3 or F4 on this screen to select “Select
ECO display target” or “Reset ECO display
data” and press F6, and the screen changes.
Auto-low idle setting
q Select “Auto-low idle setting” on the user menu

screen and press F6, and the screen changes
to the Auto-low idle setting screen.
q In this menu, you can select the auto-decelera-
tion speed or low idle speed to be set when the
auto-deceleration switch is pressed.
ON : Low idle speed
OFF: Auto-deceleration speed
PC2000-8 77
Truck counter correction/clearing q Select “Correct/Clear truck counter” on the

user menu screen and press F6, and the
screen changes to the “Correct/Clear truck
counter screen”.
q In this menu, you can correct/clear all the truck
counter values at a time or one by one.
q The contents of the menu are as follows from
the top.
A. Correct/Clear truck counter 1
B. Correct/Clear truck counter 2
C. Clear truck counters 1 and 2
On screen A or B, the counter value is increased or
decreased by 1 in the range between 0 and 99
each time the F3 or F4 switch is pressed. The cur-
rently adjusted value is displayed in the box on the
right side and entered by pressing F6.
If F5 is pressed, the screen is finished without
entering the currently adjusted value.
If F1 is pressed, the counter value is cleared.
On screen C, if F6 is pressed, the values of both
truck counters 1 and 2 are cleared to 0.
If F5 is pressed, the screen is finished without
clearing the counter values.
78 PC2000-8
Hydraulic fan reverse setting q While the fans are rotating in reverse, the
q Select “Reverse hydraulic fans” on the user screen shown below is displayed.
menu screen and press F6, and the screen q To return the hydraulic fans to the normal
changes to the screen to reverse the hydraulic direction, press F5 and change the screen to
fans. screen D.
q The hydraulic fans (2 units) can be reversed by
operating according to the guidance shown on
the screen.
q The user menu screen changes to screen A
shown below.
q While this screen is displayed, the fans are rotat-
ing in the normal direction. If F6 is pressed, the
fans are reversed and the screen changes to
screen B.
q To carry out the operation to return the hydrau-

lic fans to the normal direction, press F6, and
the screen changes to screen E.
q If F5 is pressed or no switch is operated for 5
seconds, the screen returns to screen C.
q While the fan rotation direction is being changed,

the screen shown below is displayed. After the
changing operation is finished and the hydraulic
fans rotate in reverse, the screen changes to
screen C automatically.
q While the fan rotation direction is being changed,

the screen shown below is displayed. After the
changing operation is finished and the hydraulic
fans rotate forward, the screen changes to the
normal screen automatically.
PC2000-8 79
q If the engine coolant temperature is above Idle stop guidance function

80°C and the hydraulic oil temperature is This function displays guidance to control unneces-
below 20°C or above 85°C, the screen shown sary fuel consumption. It is displayed only when all
below is displayed. In this case, the hydraulic the following conditions are met.
fans cannot be reversed. q “Energy saving guidance display” of the ser-
q If F5 is pressed, the screen changes to the vice menu is specified to ON.
user screen. q No operation is made at least 5 min. and the
engine is running at idle.
q No error or caution (excluding low hydraulic oil
temperature) is occurring.
This screen switches to the normal screen if one of

the following conditions occurs.
q When the lever is operated
q When F5 is pressed
q When an error or caution occurs
When you switch to the normal screen by pressing
F5, this screen does not appear even if the engine
continues to run at idle. If the engine continues to
run at least 5 min. after operating the lever, this
screen appears again.
80 PC2000-8
Service meter check function 1 Display LCD check function 1

q If you continuously press auto-deceleration q Continuously pressing the buzzer cancel
switch (1) and buzzer cancel switch (2) at the switch (1) and F2 at the same time on the nor-
same time when setting the starting switch to mal screen causes the entire LCD to light in
the OFF position, the service meter will appear white. Release F2 and buzzer cancel switch in
on the screen in 3 to 5 sec. order.
q The liquid crystal display panel may have black
spots (which do not light up) or bright spots
(which stay on).
Products having 10 or less black or bright
spots conform the product specification; such
the condition is quite normal.
q When these switches are released, the LCD

goes out.
a Continuous operation of the machine monitor
may display blue bright spots on this screen; it
is quite normal.
q Pressing any function switch returns to the pre-

vious screen.
PC2000-8 81
User code/failure code display function 1 q If the telephone number has been set in the
q If there is any problem in machine operation, service menu, the screen shows the telephone
the user code and failure code are displayed symbol and telephone number simultaneously
on the monitor to advise the operator of the with the user code/failure code. (For informa-
steps to take. tion on how to input and set the telephone
q These codes appear on the normal screen. number, see “Special functions of machine
q On the normal screen, user code (1) and fail- monitor” in the Testing and adjusting section.)
ure code (2) are displayed on the portion for
the hydraulic oil temperature gauge.
q If multiple user codes or failure codes are issued,

they are displayed alternately every 2 sec. The
drawing below shows the case two types of user
codes and failure codes are displayed.
82 PC2000-8
Sensor 1
q The signals from the sensors are input to the engine controller, pump controller, machine monitor, and
VHMS controller.
q The contact type sensors are always connected at one end to the chassis GND.
Name of sensor Type of sensor When normal When abnormal Input controller
Fuel level Resistance — — Monitor
Coolant level Contact ON (closed) OFF (open) Monitor
Air cleaner clogging Contact OFF (open) ON (closed) Monitor
Engine oil level Contact ON (closed) OFF (open) Monitor
Fuel level (low, mid, high) Contact — — Pump controller 1
Main pump pressure
Analog — — Pump controller 1
Fan pump pressure
Jet sensor differential pressure Analog — — Pump controller 1
Hydraulic oil temperature Resistance — — Pump controller 2
Travel PPC pressure switch Contact — — Pump controller 2
Work equipment PPC pressure sensor Analog — — Pump controller 2
Auto-greasing pressure Analog — — Pump controller 2
Hydraulic filter clogging Contact ON (open) OFF (closed) VHMS controller
Hydraulic oil level Contact ON (closed) OFF (open) VHMS controller
VHMS hydraulic oil temperature Resistance — — VHMS controller
PTO oil temperature Resistance — — VHMS controller
Ambient temperature Resistance — — VHMS controller
Blowby temperature Resistance — — VHMS controller
Exhaust temperature Analog — — VHMS controller
Exhaust temperature sensor AMP Analog — — VHMS controller
Coolant level sensor
1. Reservoir tank 2. sensor 3. Connector
PC2000-8 83
Detail of sensor
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
Fuel level sensor
1. Float
2. Switch
3. Connector
4. Variable resistor
84 PC2000-8
Air cleaner clogging sensor
Engine oil level sensor
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
Fuel level (low, mid, high) sensor
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
PC2000-8 85
Main pump oil pressure sensor
1. Sensor
2. Connector
Operation
q The oil pressure applied from the pressure q Relationship between pressure (P) and output
intake part presses the diaphragm of the oil voltage (E) is as follows.
pressure sensor, the diaphragm is deformed.
q The gauge layer facing the diaphragm mea-
sures the deformation of the diaphragm by the
change of its resistance, then converts the
change of the resistance into a voltage and
transmits it to the amplifier (voltage amplifier).
86 PC2000-8
Hydraulic oil temperature sensor, PTO oil temperature sensor
1. Thermistor 3. Wire 5. Tube

2. Tube 4. Body 6. Connector
Grease pump discharge pressure sensor
1. Sensor
2. Connector
Hydraulic filter clogging sensor
1. Block
2. Sensor
3. Wire
4. Connector
PC2000-8 87
Boom, arm, bucket, swing PPC oil pressure sensor
1. Sensor
2. Connector
Function q Relationship between pressure (P) and output

q The PPC oil pressure sensor is installed to 6 voltage (E) is as follows.
places of the junction block.
q This sensor senses the operating condition of
each actuator by the PPC pressure and sends
it to the pump controller.
Operation
q The oil pressure applied from the pressure
intake part presses the diaphragm of the oil
pressure sensor, the diaphragm is deformed.
q The gauge layer facing the diaphragm mea-
sures the deformation of the diaphragm by the
change of its resistance, then converts the
change of the resistance into a voltage and
transmits it to the amplifier (voltage amplifier).
88 PC2000-8
Hydraulic oil level sensor
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
VHMS hydraulic oil temperature sensor, Ambient temperature sensor
1. Thermistor 3. Wire 5. Tube

2. Tube 4. Body 6. Connector
PC2000-8 89
Engine blow-by pressure sensor
1. Sensor Specifications and function

2. Connector q Pressure range:
3. Ambient pressure intake tube 0 – 20 kPa {0 – 2,040 mmH2O}
q Pressure limit:
A: GND (Black) –20 – 100 kPa {–2,040 – 10,200 mmH2O}
B: Power source (Red) q Power supply voltage: 5 ± 0.25 V
C: Output (White) q Output characteristics: See graph.
q The blow-by pressure sensor is a relative pres-
sure sensor of low pressure type, which mea-
sures the difference between the pressure in
the crankcase and ambient pressure.
q The pressure in the crankcase is applied to the
end side of the sensor and the ambient pres-
sure is applied to the wiring harness side.
90 PC2000-8
Exhaust temperature sensor
Exhaust temperature sensor amplifier
Travel PPC pressure switch
PC2000-8 91
VHMS controller
92 PC2000-8
Location of pins
CN1 CN2
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
1 NC — A1 NC —
2 PWR_OUT_24V Output A2 AIS_PTO. OIL TMP. SENS Input
3 PWR_OUT_12V Output A3 NC —
4 NC — A4 AIS_ALTR_VOLT_VHMS Input
5 PWR_OUT_5V Output A5 AIS_EX. GAS. TMP. SENS. LBR Input
6 PWR_IN_BATT Input A6 AIS_EX. GAS. TMP. SENS. RBR Input
7 PWR_IN_BATT Input A7 AIS_EX. GAS. TMP. SENS. RBF Input
8 PWR_IN_BRY Input A8 NC —
9 PWR_IN_BRY Input A9 DIS_SEL0 (GND) Input
10 NC — A10 AIS_AIR. TMP. SENS Input
11 GND_PWR — A11 AIS_HYD_OIL_LOW_TMP. SENS Input
12 GND_PWR — A12 GND_SIG —
13 NC — A13 GND_SIG —
14 DOS_DUMP_COUNT_BUZZER Output A14 NC —
15 NC — A15 AIS_FUEL_REMAIN. SENS Input
16 NC — A16 AIS_EX. GAS. TMP. SENS. LBF Input
17 PWR_CTR_KEY Input A17 *DIS_WUL Input
18 NC — A18 AIS_BLOWBY. PRES. SENS Input
19 GND_PWR — B1 AIS_HYD_FILTER_CLOG. SENS Input
20 GND_PWR — B2 AIS_HYD_OIL_LEVEL. SENS Input
B3 NC —
B4 NC —
B5 NC —
B6 DIS_WUH (GND) Input
B7 NC —
B8 NC —
B9 GND_SIG —
B10 NC —
B11 NC —
B12 DIS_SEL1 (GND) Input
NC: Not connected
PC2000-8 93
CN3 CN4
A1 NC — A1 NC —
A2 DIS_CAB. OUT. DL. SW Input A2 NC —
A3 NC — A3 NC —
A4 NC — A4 COMM_CAN_H_1 (KOMNET) Input/Output
A5 DIS_ORB Input A5 NC —
A6 NC — A6 COMM_CAN_H_0 (MMS) Input/Output
A7 NC — A7 NC —
A8 NC — A8 NC —
A9 DIS_SEL2 (OPEN) Input A9 GND_COMM —
A10 Truck_COUNT_SW1 Input A10 COMM_232C_RXD_0 (PC Tool) Input
A11 Truck_COUNT_SW2 Input A11 COMM_232C_TXD_0 (PC Tool) Output
A12 NC — A12 COMM_CAN_L_1 (KOMNET) Input/Output
A13 GND_SIG — A13 NC —
A14 NC — A14 COMM_CAN_L_0 (MMS) Input/Output
A15 NC — B1 NC —
A16 NC — B2 NC —
A17 GND_SIG — B3 GND_COMM (Orbcomm) —
A18 NC — B4 COMM_232C_TXD_1 (Orbcomm) Output
B1 NC — B5 NC —
B2 NC — B6 NC —
B3 NC — B7 NC —
B4 NC — B8 NC —
B5 NC — B9 GND_COMM (Orbcomm) —
B6 NC — B10 COMM_232C_RXD_1 (Orbcomm) Input
B7 NC —
B8 NC —
NC: Not connected
B9 GND_SIG —
B10 NC —
B11 NC —
B12 DIS_SEL3 (OPEN) Input
94 PC2000-8
ORBCOMM terminal 1
1. Communication antenna connection

2. DRC connector (40-pole) connection
Outline
q The ORBCOMM terminal obtains various kinds of machine information recorded in the VHMS controller
and transmits them via the wireless communication antenna. It has a CPU (Central Processing Unit)
and wireless communication function.
q This terminal has an LED lamp and a 7-segment display lamp used for inspection and troubleshooting.
Input/Output signals
q DRC connector
1 NC Input 15 NC Output
4 Communication signal 232C_TxD Input 18 NC Output
5 Communication signal 232C_RxD Output 19 VHMS controller signal Output
6 NC — 20 NC Output
7 NC Input/Output 21 NC Input
9 NC — 23 NC Input
11 GND_232C — 25 NC Input
29 GND —
30 NC Output
31 NC Input
32 NC Input
33 NC Input
34 NC Input
35 NC Output
36 ACC input (analog) Input
37 Power supply GND —
38 Power supply GND —
39 Unswitched power supply (12/24 V) Input
40 Unswitched power supply (12/24 V) Input
PC2000-8 95
SEN01623-00
© 2006 KOMATSU
All Rights Reserved
96
SEN02006-00
PC2000-8

PC2000-8 20001 and up
20 Standard value table 1
Standard service value table

Standard service value table ........................................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ............................................. 2
Standard service value table for chassis .............................................................................................. 3
PC2000-8 1
SEN02006-00 20 Standard value table
Standard service value table 1
Standard service value table for testing, adjusting, and troubleshooting1
Applicable model PC2000-8
Engine SAA12V140E-3
Category
Standard
Service limit
Item Measurement conditions Unit value for new
value
machine
Max. speed at no load rpm 1,980 ± 50 1,980 ± 50

Performance
Speed Min. speed at no load rpm 825 ± 50 825 ± 50

Rated speed rpm 1,800 1,800
Necessary At 0°C (without starting aid) rpm Min. 110 —
speed for
starting At –20°C (with starting aid) rpm Min. 100 —
Air boost kPa Min. 125.70

At rated output —
pressure {mmHg} {Min. 950}
Air intake and exhaust system
Exhaust
Whole speed range (20°C) °C Max. 700 750
temperature
Bosch
At sudden acceleration (Low to High) Max. 4.5 5.5
index
Exhaust gas Bosch
At rated output Max. 1.0 2.0
color index
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 ± 0.02 0.35 ± 0.02
Valve clearance
Exhaust valve mm 0.57 ± 0.02 0.57 ± 0.02
Compression Engine oil temperature: 40 – 60°C MPa Min. 4.1 2.8
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 42} {29}
Body
Blow-by At rated output kPa Max. 2.94 5.88

pressure Engine coolant temperature: Min. 70°C {mmH2O} {Max. 300} {600}
At rated output SAE0W30E0S MPa 0.29 – 0.44 0.2
Lubrication system
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {3.0 – 4.5} {2.0}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.06
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 0.8} {0.6}
Oil temperature Whole speed range (Oil in oil pan) °C 90 – 110 120
Alternator belt
— Deflection under finger pressure of 59 N {6 kg} mm 20 20
tension
a The above values are calculated when the engine is installed in the chassis.
2 PC2000-8
Standard service value table for chassis 1

Category
Standard
Service limit
Item Measurement conditions Unit value for new
value
machine
• Engine coolant temperature:

Within operating range
• Hydraulic oil temperature: 45 – 55°C
All pumps at relief 1,780 ± 100 1,780 ± 100
• Engine at high idle
• Working mode: P
• Boom up relief
Engine speed
• Engine coolant temperature:

Within operating range rpm
Heavy lift ON
+ 1,780 ± 100 1,780 ± 100
All pumps at relief
• Working mode: P & heavy lift
• Boom up relief
Auto-deceleration
• Auto-deceleration switch ON 1,400 ± 100 1,400 ± 100
actuated
• All control levers at neutral
Boom Lo control valve • Engine stopped
Spool stroke of control valves
• Stroke (a) or (b) side

Boom Hi control valve
Arm Lo control valve
Arm Hi control valve
16 ± 0.5 16 ± 0.5
Bucket Lo control valve
Bucket Hi control valve
Swing control valve
Travel control valve
Boom control lever N o Raise, Lower mm 85 ± 10 85 ± 10
Arm control lever N o In, Out 85 ± 10 85 ± 10

Travel of control levers
• Center of lever knob

Bucket control lever • Read max. value to N o Curl, Dump 85 ± 10 85 ± 10
end of travel (Exclude
Swing control lever play at neutral.) N o R.H., L.H. 85 ± 10 85 ± 10
• Engine stopped
N o F, R
Travel control lever 115 ± 12 115 ± 12
(L.H., R.H.)
Work equipment,
Play of control levers Max. 10 Max. 15
swing, travel
PC2000-8 3

Category
Standard value Service limit

Item Measurement conditions Unit
for new machine value
15.7 ± 4.9 15.7 ± 4.9

Boom control lever
{1.6 ± 0.5} {1.6 ± 0.5}
Operating effort of control levers
• Hydraulic oil temperature: 45 – 55°C 15.7 ± 4.9 15.7 ± 4.9

Arm control lever
• Engine at high idle {1.6 ± 0.5} {1.6 ± 0.5}
• Center of lever knob 12.7 ± 3.9 12.7 ± 3.9
Bucket control lever • Measure max. value to end of travel {1.3 ± 0.4} {1.3 ± 0.4}
N {kg}
12.7 ± 3.9 12.7 ± 3.9
Swing control lever
{1.3 ± 0.4} {1.3 ± 0.4}
21.6 ± 5.4 21.6 ± 5.4
Lever
Travel control lever, {2.2 ± 0.6} {2.2 ± 0.6}
pedal 98.1 ± 25.4 98.1 ± 25.4
Pedal
{10 ± 2.5} {10 ± 2.5}
+1.0
29.4 ± 1.0 29.4
–2.0
Normal
{300 ± 10} +10
{300 }
RAISE
–20
+1.0
At heavy 32.1 ± 1.0 32.1
–2.0
Boom relief pressure lift {150 ± 20} +10
{327 –20
}
• Hydraulic oil tem-
perature: 45 – 55°C 14.7 ± 2.0 14.7 ± 2.0
Normal
LOWER
• Engine at high idle {150 ± 20} {150 ± 20}

• Working mode: P At machine 28.4 ± 2.0 28.4 ± 2.0
• Pump outlet push-up {290 ± 20} {290 ± 2.0}
pressure when
measured circuit is +1.0
29.4 ± 1.0 29.4
relieved –2.0
Arm relief pressure
{300 ± 10} +10
• Relieve either travel {300 –20
}
circuit.
Hydraulic pressure
+1.0
29.4 ± 1.0 29.4
–2.0
Bucket relief pressure
MPa {300 ± 10} +10
{300 –20
}
{kg/cm2}
+1.0
29.4 ± 1.0 29.4
–2.0
Swing relief pressure
{300 ± 10} +10
{300 –20
}
+1.0
Relieve L. H. travel: L1/L2 (P1R/ P2R) 32.9/33.8 ± 1.0 32.9/33.8
–2.0
Travel relief pressure
Relieve R. H. travel: R1/R2 (P1F/ P2F) {335/345 ± 10} +10
{335/345 –20
}
• Hydraulic oil temperature: +0.49 +0.49

3.24 3.24
–0 –0.20
Control pressure 45 – 55°C
+5 +5
• Engine at high idle {33 0 } {33 –2 }
All control
Max. 0.59 Max. 0.59
• Hydraulic oil tem- levers at neu-
Pump EPC solenoid {Max. 6} {Max. 6}
perature: 45 – 55°C tral
valve output
• Engine at high idle Travel under no
pressure 1.11/2.04 ± 0.39 1.11/2.04 ± 0.39
• Working mode: P load (Lever full)
{11.3/20.8 ± 4.0} {11.3/20.8 ± 4.0}
(P1/P2)
4 PC2000-8

Category

All control
Min. 1.28 Min. 1.28
• Hydraulic oil tem- levers at neu-
{Min. 13.1} {Min. 13.1}
Jet sensor differential perature: 45 – 55°C tral
pressure • Engine at high idle
Hydraulic pressure
• Working mode: P Travel under no Max. 0.17 Max. 0.17

load (Lever full) {Max. 1.7} {Max. 1.7}
MPa
• Hydraulic oil temperature: 45 – 55°C {kg/cm2} +0.8 +0.8
PPC valve output 2.9 2.9
–0.2 –0.2
pressure +8 +8
• Control lever at stroke end {30 –2 } {30 –2 }

Max. 2.0 Max. 2.9
Oil pressure drop • Difference between relief pressure at
{Max. 20} {Max. 30}
high idle and that at low idle
All control
levers at neu- Min. 2.77 Min. 2.77
Output voltage of dif- tral
perature: 45 – 55°C
ferential pressure V
• Engine: High idle
sensor Travel under no
Electronic control
• Working mode: P
load Max. 1.40 Max. 1.40
(Lever full)
All control
levers at neu- 220 ± 60 220 ± 60
tral
perature: 45 – 55°C
Pump EPC current mA
• Engine: High idle
Travel under no
• Working mode: P
load 450/675 ± 60 450/675 ± 60
(Lever full)
Swing
Overrun when stop- deg. Max. 62 Max. 80

ping swing • Hydraulic oil temperature: 45 – 55°C (mm) (Max. 1,593) (Max. 2,056)
• Bucket: No load
• Working mode: P
• Stop after swinging one turn and mea-
sure distance that swing circle moves
PC2000-8 5

Category

90° 5.7 ± 0.6 Max. 6.8
Time taken to start • Hydraulic oil temperature: sec.

swing 45 – 55°C
• Bucket: No load
180° 9.0 ± 0.9 Max. 10.8
• Working mode: P
• Time taken to swing 90° and
180° from starting position
Time taken to swing sec. 57.5 – 67.5 Max. 70

• Bucket: No load
Swing
• Working mode: P
• Swing one turn, then measure time
taken to swing next 5 turns
Hydraulic drift of
• Hydraulic oil temperature: 45 – 55°C mm 0 0
swing
• Engine stopped
• Set machine on 15° slope, and set
upper structure at 90° to the side.
• Make match marks on inner race and
outer race of circle.
• Measure distance that match marks
move apart after 5 minutes.
Leakage from swing
• Swing lock switch: ON l/min Max. 5 Max. 10
motor
• Leakage in 1 minute during swing
relief
6 PC2000-8

Category

Travel speed
sec. 90.5 – 110.5 90.5 – 110.5
(Idle travel)
• Working mode: P
• Raise track on one side at a time,
rotate one turn, then measure time
taken for next 5 turns with no load.
Travel speed
sec. 24.2 – 29.6 24.2 – 29.6
(Actual travel) • Hydraulic oil temperature: 45 – 55°C
• Working mode: P
Travel
• On level ground
• Run up for at least 10 m, and mea-
sure time taken to travel next 20 m on
flat ground.

• Working mode: P
Travel deviation mm Max. 200 Max. 220
• Travel speed: Lo
• On hard and level ground
• Measure travel deviation (x) in travel
of 20 m after running up 10 m.
PC2000-8 7

Category

Hydraulic drift of travel mm 0 0

• Engine stopped
Travel
• Stop machine on 12° slope with sprocket

at uphill end of machine.
• Measure the distance the machine
moves in 5 minutes.
Leakage of travel
• Travel: Lock sprocket. l/min Max. 25 Max. 30
motor
• Measure leakage in 1 minute during
travel relief.
Total work equip-

ment
Max. 1,200 Max. 1,800
(hydraulic drift at
(Max. 650) (Max. 1,000)
tip of bucket
teeth)
• Measure extraction or retraction distance

Hydraulic drift of work equipment
of each cylinder and lowering distance of

Boom cylinder
bucket tooth tip from above posture. Max. 60 Max. 90
(amount of retrac-
Rated load on work equipment (Max. 35) (Max. 50)
tion of cylinder)
Work equipment
Backhoe specification: 21,600 kg

• Measure on level and flat ground.
• Set lever in neutral. mm
• Stop engine.
Arm cylinder • Measure just after setting.
Max. 165 Max. 250
(amount of exten- • Measure lowering distance every 5 min-
utes. Judge by lowering distance in 15 (Max. 70) (Max. 105)
sion of cylinder)
minutes.
• Values in ( ) are standard values when
no load is applied to work equipment.
Bucket cylinder
Max. 50 Max. 75
(amount of retrac-
(Max. 15) (Max. 25)
tion of cylinder)
8 PC2000-8

Category
Standard value for

Item Measurement conditions Unit Service limit value
new machine
Backhoe Backhoe
specification specification
*RAISE
Boom
Lower bucket 7.5 ± 0.8 Max. 9.0
tooth to ground.
• Run engine at full throttle.

Extract cylinder to • Set in mode P
stroke end.
LOWER
• Hydraulic oil temperature:
45 – 55°C 5.3 ± 0.5 Max. 6.4
Work equipment speed
7.5 ± 0.8 Max. 9.0

IN
Work equipment
Arm
Retract cylinder to
stroke end. sec.
Extract cylinder to
stroke end.
*OUT
• Run engine at full throttle. 5.2 ± 0.5 Max. 6.2

• Set in mode P
45 – 55°C
*CURL
5.0 ± 0.5 Max. 6.0

Bucket
Retract cylinder to
stroke end.
Extract cylinder to • Run engine at full throttle.

DUMP
stroke end. • Set in mode P 3.9 ± 0.4 Max. 4.7

45 – 55°C
PC2000-8 9

Category
Standard value for

new machine
Boom Max. 6 Max. 6
• Time required to raise chassis

after bucket reaches ground
• Run engine at slow speed.
45 – 55°
Time lag
sec.
Work equipment
Arm Max. 5 Max. 5
• Time from stop of arm to start.

45 – 55°C
Bucket Max. 4 Max. 4
• Time from stop of bucket to

start.
45 – 55°C
Oil leakage
Cylinders • Hydraulic oil temperature: Max. 5 Max. 20

45 – 55°C
cc/min
Center swivel • Hydraulic oil pressure:
29.4 ± 1.0 MPa {300 ±10 kg/cm2} Max. 10 Max. 100
joint
45 – 55°C STD: 840 ± 50 STD: 840 ± 50
Fan speed rpm
• Engine: High idle +55°C spec.: 1,100 ± 50 +55°C spec.: 1,100 ± 50
• Fan 100% speed mode
Fan (Radiator)
• Hydraulic oil temperature: STD: 1.69 ± 0.39 STD: 1.69 ± 0.39

Output pressure of fan
45 – 55°C MPa {17.2 ± 4.0} {17.2 ± 4.0}
pump EPC solenoid
• Engine: High idle {kg/cm2} +55°C spec.: 1.32 ± 0.39 +55°C spec.: 1.32 ± 0.39
valve
• Fan 100% speed mode {13.5 ± 4.0} {13.5 ± 4.0}
Fan pump EPC cur- 45 – 55°C STD: 625 ± 50 STD: 625 ± 50
mA
rent • Engine: High idle +55°C spec.: 555 ± 50 +55°C spec.: 555 ± 50
10 PC2000-8

Category
Standard value for

new machine

45 – 55°C STD: 760 ± 50 STD: 760 ± 50
Fan speed rpm
• Engine: High idle +55°C spec.: 1,100 ± 50 +55°C spec.: 1,100 ± 50
Fan (Oil cooler)
• Hydraulic oil temperature: STD: 1.81 ± 0.39 STD: 1.81 ± 0.39

Output pressure of fan
45 – 55°C MPa {18.5 ± 4.0} {18.5 ± 4.0}
pump EPC solenoid
• Engine: High idle {kg/cm2} +55°C spec.: 1.32 ± 0.39 +55°C spec.: 1.32 ± 0.39
valve
• Fan 100% speed mode {13.5 ± 4.0} {13.5 ± 4.0}
Fan pump EPC cur- 45 – 55°C STD: 650 ± 50 STD: 650 ± 50
mA
rent • Engine: High idle +55°C spec.: 555 ± 50 +55°C spec.: 555 ± 50
Pump performance
Delivery amount of
• See next page l/min See next page
hydraulic pump
PC2000-8 11
Category
Delivery amount of one hydraulic pump (P1 Pump, per one pump)
PC2000 No. 1 PUMP IQ standards at 100 kg/cm2
Performance of hydraulic pump
• Pump speed: At 1,729 rpm

• Pump discharge pressure: 9.8 MPa {100 kg/cm2}
Standard value Judgement

Test pump
Check point for delivery amount Q standard lower limit Q
Test pump EPC current (mA)
(l/min) (l/min)
As desired I See graph See graph
12 PC2000-8
Category
Delivery amount of one hydraulic pump (P2 Pump, per one pump)
PC2000 No. 2 PUMP IQ standards at 100 kg/cm2
Performance of hydraulic pump
• Pump speed: At 1,423 rpm

• Pump discharge pressure: 9.8 MPa {100 kg/cm2}
Standard value Judgement

Test pump
Check point for delivery amount Q standard lower limit Q
Test pump EPC current (mA)
(l/min) (l/min)
As desired I See graph See graph
PC2000-8 13
SEN02006-00
© 2006 KOMATSU
All Rights Reserved
14
SEN02007-00
PC2000-8

PC2000-8 20001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Testing and adjusting, Part 1........................................................................................................................... 3
Tools for testing, adjusting, and troubleshooting .................................................................................. 3
Measuring engine speed...................................................................................................................... 6
Testing air boost pressure .................................................................................................................... 7
Testing exhaust temperature................................................................................................................ 8
Testing exhaust color ........................................................................................................................... 9
Adjusting valve clearance ...................................................................................................................11
Testing compression pressure ........................................................................................................... 13
Testing blow-by pressure ................................................................................................................... 15
Testing engine oil pressure ................................................................................................................ 16
Handling fuel system parts ................................................................................................................. 17
Releasing residual pressure in fuel system........................................................................................ 17
Testing fuel pressure .......................................................................................................................... 18
Testing leakage from pressure limiter and return rate from injector ................................................... 19
Bleeding air from fuel circuit............................................................................................................... 22
Bleeding air from fuel circuit (low-grade fuel specification) ................................................................ 26
PC2000-8 1
SEN02007-00 30 Testing and adjusting
Testing fuel system for leakage .......................................................................................................... 28

Testing and adjusting air conditioner compressor belt tension........................................................... 30
2 PC2000-8
Testing and adjusting, Part 1 1

Tools for testing, adjusting, and troubleshooting 1
symbol
Testing and adjusting
Q’ty
Part No. Part name Remarks
item
Measuring intake air

pressure (boost pres- A 799-201-2202 Boost gauge kit 1 –101 to 200 kPa {–760 to 1,500 mmHg}
sure)
Measuring exhaust 1 799-101-1502 Digital thermometer 1

B –99.9 to 1,299ºC
temperature 2 799-201-1150 Adapter connector 1
Measuring exhaust gas 1 799-201-9001 Handy smoke checker 1 Bosch index: 0 to 9 (With standard color)
J
color 2 Purchased Smoke meter 1
Adjusting valve clear-
C Purchased Clearance gauge 1 (Intake: 0.35 mm, Exhaust: 0.57 mm)
ance
1 795-502-1590 Compression gauge 1 0 to 6.9 MPa {0 to 70 kg/cm2}
Measuring compres-
D 795-471-1310 Adapter 1 For 140E-3, 5 engine
sion pressure 2
6261-71-6150 Gasket 1 For 140E-3, 5 engine
Measuring blow-by
E 1 799-201-1504 Blow-by checker 1 0 – 10 kPa {0 – 1,000 mmH2O}
pressure
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil
F
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Testing fuel pressure G 2 795-471-1450 Adapter 1 8 x 1.25 mm (male) o R1/8 (female)

799-101-5220 Nipple 1
3 Size: 10 × 1.25 mm
07002-11023 O-ring 1
4 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 6151-51-8490 Spacer 1 Ø 14
2 6141-71-1710 Joint 1 Ø 10
3 Purchased Hose 1 Inside diameter: approx. 11 mm
Testing fuel return rate
of injector and leakage H 4 Purchased Hose 1 Inside diameter: approx. 17 mm
of pressure limiter
5 Purchased Measuring cylinder 1
6 Purchased Stopwatch 1
7 07376-70315 Plug 1 Size: 03
Measuring clearance of Dial gauge (with mag-
K Purchased 1 With magnet
swing circle bearing net)
Gas filling in HIC circuit Charge valve assem-
M 792-610-1700 1
accumulator bly
PC2000-8 3
symbol
Q’ty
item

1 {25, 60, 400, 600 kg/cm2}
control circuit oil pres- P 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
sure 799-101-5220 Nipple 1 Size: 10 × 1.25 mm
2
07002-11023 O-ring 1
1 {25, 60, 400, 600 kg/cm2}
control signal of Q 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
piston pump 799-101-5220 Nipple 2 Size: 10 × 1.25 mm
2
07002-11023 O-ring 2
Measuring fan speed R 799-203-8001 Multiple tachometer 1 L: 60 – 2000 rpm, H:60 – 19,999 rpm
1 {25, 60, 400, 600 kg/cm2}
Measuring fan pump
EPC solenoid output S 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
pressure 799-101-5220 Nipple 1 Size: 10 x 1.5 mm
2
07002-11023 O-ring 1
1 {25, 60, 400, 600 kg/cm2}
Measuring PPC valve 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
output pressure, sole- 799-401-3200 Adapter 1 Size: 03
T
noid valve outlet pres- 2
sure 02896-11009 O-ring 1
799-401-3300 Adapter assembly 1
3
02896-11012 O-ring 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Measuring outlet pres- 799-401-3200 Adapter 1 Size: 03
sure of solenoid valve, 2
swing PPC shuttle U 02896-11009 O-ring 1
valve, and swing prior- 799-401-3300 Adapter 1 Size: 04
ity selector valve 3
02896-11012 O-ring 1
799-101-5220 Nipple 2 Size: 10 × 1.25 mm
4
07002-11023 O-ring 2
799-608-3211 Diskette 1
VHMS controller initial 1
799-608-3220 Wiring harness 1
setting and replace- W
ment time setting Windows 98/2000/Me/XP,
2 Purchased Note type PC 1
with RS232C terminal
Measuring coolant tem-
perature and oil tem- X 799-101-1502 Digital thermometer 1 –99.9 to 1,299 ºC
perature
4 PC2000-8
symbol
Q’ty
item
Measuring operating 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}

effort and pressing Y
force 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
Measuring stroke and

Z Purchased Scale 1
hydraulic drift
Measuring work equip-
AA Purchased Stopwatch 1
ment speed
Measuring voltage and
AB Purchased Tester 1
resistance
799-601-7400 T-adapter assembly 1 SWP, X, M connector
799-601-7500 T-adapter assembly 1 AMP070 connector
799-601-9000 T-adapter assembly 1 DT, HD30 connector
799-601-9300 T-adapter assembly 1 DRC26 – 24, 40 pin
799-601-7360 Adapter 1 Relay (5 pins)
799-601-9420 T-adapter 1 Pressure sensor
799-601-3450 Adapter 1 VHMS download harness
799-601-4100 T-adapter assembly 1 Engine-related connectors
795-799-5530 Adapter 1 Engine coolant, oil, fuel temperature
795-799-5540 Adapter 1 Boost temperature sensor
Troubleshooting of sen-
sors and wiring har- — 799-601-4130 T-adapter 1 Ne sensor
ness
799-601-4150 T-adapter 1 Oil pressure sensor
799-601-4211 T-adapter 1 Controller (50 poles)
799-601-4240 Socket 1 Ambient pressure sensor
799-601-4250 Socket 1 Boost pressure sensor
799-601-9020 T-adapter 1 Injector
799-601-9420 T-adapter 1 Common rail pressure sensor
799-601-9430 Adapter 1 Supply pump PCV
799-601-9030 T-adapter 1 G sensor
PC2000-8 5
Measuring engine speed 1 4. Measuring all-pump relief speed

1) Start the engine and set the fuel control
dial in the high idle position (MAX).
a Measure the engine speed under the following 2) Set the working mode switch in the P-mode
condition. position.
q Engine coolant temperature: Within oper- 3) Turn the heavy lift switch OFF.
ating range 4) Relieve the boom circuit by raising the
q Hydraulic oil temperature: 45 – 55°C boom and measure the engine speed.
1. Preparation work 5. Measuring heavy-lift ON + all-pump relief

Turn the starting switch ON and set the speed
machine monitor to “Monitoring”. 1) Start the engine and set the fuel control
a For the operating method, see “Special dial in the high idle position (MAX).
functions of machine monitor”. 2) Set the working mode switch in the P-
a Monitoring code: 01002 Engine speed mode position.
01006 Engine speed 3) Turn the heavy lift switch ON.
a Code 01002 is information of the engine 4) Relieve the boom circuit by raising the
controller and code 01006 is information boom and measure the engine speed.
of the pump controller. The engine speed
can be measured with either of those 6. Measuring auto-deceleration ON speed
codes. 1) Start the engine and set the fuel control
a The engine speed is displayed in rpm. dial in the high idle position (MAX).
2) Turn the auto-deceleration switch ON.
3) Set the work equipment control, swing
control, and travel control levers in neutral.
When the auto-decelerator operates,
measure the engine speed.
a The engine speed lowers to a certain
level about 5 seconds after all the
levers are set in neutral. This level is
the auto-deceleration speed.
2. Measuring low idle speed

dial in the low idle position (MIN).
2) Set the work equipment control, swing con-
trol, and travel levers in neutral and measure
the engine speed.
3. Measuring high idle speed

dial in the high idle position (MAX).
2) Set the working mode switch to the P-mode
position.
3) Turn the auto-decelerator switch OFF.
6 PC2000-8
Testing air boost pressure 1 4. Install nipple [1] of boost gauge kit A and con-
nect it to gauge [2].
a Testing tools for air boost pressure 5. Run the engine at the rated output and test the
Symbol Part No. Part name air boost pressure. (P mode and relieve boom-
raise)
799-201-2202 Boost gauge kit
A
790-401-2220 Hose
k Be careful not to touch any hot part when

removing or installing the testing tools.
1. Equipped boost pressure sensor for engine

control system.
The boost pressure signal can be checked by
monitoring function equipped machine monitor.
q Monitoring code: 36500 L/B boost pres-
sure.
a Operation procedure is referred to the
“Special function of machine monitor”.
2. If the testing tools are used, check procedure 6. After finishing testing, remove the testing tools
is as follows. and return the removed parts.
3. Remove air boost pressure pickup plug ((L1)

on left bank or (R1) on right bank) from the bot-
tom of the air intake connector.
a Example of the left bank
PC2000-8 7
Testing exhaust temperature 1 4. Points for testing of the maximum temperature

in troubleshooting.
Test the maximum exhaust temperature when
a Testing tool for exhaust temperature
work is conducted.
Symbol Part No. Part name a Use a digital thermometer with PEAK
1 799-101-1502 Digital thermometer mode.
B
2 799-201-1150 Adapter connector
5. Points for periodical testing in preventive main-
k Remove and install the testing tools after tenance service (Pm clinic).
the exhaust manifold temperature has low- 1) Start the engine and set the work mode
ered. switch to the P mode.
a Subject section for measuring includes front 2) Turn ON the heavy-lift switch.
left, rear left, front right and rear right (4 points 3) Test exhaust temperature when the
in total). engine is at high idle and the boom raise
is relieved.
1. Equipped exhaust temperature sensor for
VHMS controller system
The exhaust temperature signal can be
checked by monitoring function equipped
machine monitor.
q Monitoring code
42600 L/B 1 – 3 exhaust temperature
42601 L/B 4 – 6 exhaust temperature
42608 R/B 1 – 3 exhaust temperature
42609 R/B 4 – 6 exhaust temperature
a Operation procedure is referred to the
“Special functions of machine monitor”.
2. If the testing tools are used, check procedure

is as follows.
6. After finishing testing, remove the testing tools
3. Connect adapter connector B2 to exhaust tem- and return the removed parts.
perature sensor (1) connector and then con-
nect digital thermometer B1.
a Installation example to the front left-hand
side (LF)
8 PC2000-8
Testing exhaust color 1 2. Measuring with Smoke Meter J2

1) Insert probe [1] of Smoke Meter J2 into
the outlet port of the exhaust pipe, and
a Tools for measuring exhaust color tighten the clip to secure it to the exhaust
Symbol Part No. Part name pipe.
1 799-201-9001 Handy Smoke Checker
J Commercially
2 Smoke Meter
available
k Be careful not to touch any hot parts when

removing or installing the testing tools.
a When measuring in the field where there is no
air or electric power supply, use Handy Smoke
Checker J1; when recording formal data, use
Smoke Meter J2.
a Measure the exhaust color under the following
conditions.
q Coolant temperature: Within operating range
1. Measuring with Handy Smoke Checker J1 2) Connect the air hose and the socket of the
1) Install filter paper to Handy Smoke Checker prove hose and accelerator switch to
J1. Smoke Meter J2.
2) Insert the exhaust gas suction port into the a Keep the pressure of the air supply
exhaust pipe. below 1.5 MPa {15 kg/cm2}.
3) Start the engine. 3) Connect the power cord to the AC100V
4) Accelerate the engine suddenly or run at socket.
high idle, and operate the handle of Handy a Before connecting the cord, check
Smoke Checker J1 at the same time to that the power switch of the Smoke
collect the exhaust gas on the filter paper. Meter is OFF.
4) Loosen the cap nut of the suction pump
and fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas cannot leak.
5) Turn the power switch of Smoke Meter J2
ON.
5) Remove the filter paper and compare it with

the scale supplied to judge the condition.
6) After completing the measurement, remove
the measuring equipment and set to the
original condition.
PC2000-8 9
6) Start the engine.

7) Accelerate the engine suddenly or run at
high idle, and depress the accelerator
pedal of Smoke Meter J2 at the same time
to collect the exhaust gas color on the fil-
ter.
8) Place the filter paper used to catch the
exhaust gas color on top of at least 10
sheets of unused filter paper inside the fil-
ter paper holder, and read the value
shown.
9) After completing the measurement, remove
the measuring equipment and set to the
original condition.
10 PC2000-8
Adjusting valve clearance 1 5. Hereafter crank the engine similar way in the
firing order. Match the stamped line of the
damper to the pointer and adjust the valve
a Adjusting tool for valve clearance clearance of each cylinder.
Symbol Part No. Part name a Firing order
R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 –
Commercially
C Clearance gauge R2 – L2 – R4 – L4
available
Valve clearance adjusting method

1. Remove cylinder head cover.
2. Rotate the crankshaft forward and match

stamped line of R1.6 TOP on vibration damper
(1) to pointer (2), by setting RH No. 1 cylinder
to the compression top dead center while
watching the movement of the intake valve of
RH No. 6 cylinder.
a Crank the engine using the barring tool (B)
mounted to the front right-hand side of the
flywheel housing.
a At near the compression top dead center
of the RH No. 1 cylinder, the intake valve
of RH No. 6 cylinder moves (opens).
q The radiation on the left side of the
drawing.
3. Loosen locknut (6) of RH No. 1 cylinder adjust

screw (5). Insert a clearance gauge C of speci-
fied clearance between the crosshead (4) and
rocker arm (3) and adjust the adjustment
screw to the degree that the clearance gauge
can be moved lightly.
a Valve clearance
Air Intake valve: 0.35 mm, Exhaust valve:
0.57 mm
4. Tighten locknut (6) to secure adjustment

screw.
3 Locknut:
52.9 – 64.7 Nm {5.4 – 6.6 kgm}
a After tightening the locknut, check the
valve clearance again.
PC2000-8 11
6. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
12 PC2000-8
Testing compression pressure 1
a Testing tools for compression pressure

Symbol Part No. Part name
1 795-502-1590 Compression gauge
D 795-471-1310 Adapter
2
6261-71-6150 Gasket
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the
engine is warmed up. 4. Install adapter D2 to the mounting hole on the
(Engine oil temperature: 40 – 60°C). injector and compression gauge D1.
a Fit the gasket to the injector end without
1. Remove cylinder head cover (1) of the cylinder fail.
to be tested for compression pressure. a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
5. Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm assembly mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a See “Adjusting valve clearance”.
2. Bring the cylinder to be tested to the compres-

sion top dead center and remove rocker arm
assembly (2).
a See “Adjusting valve clearance”.
3. Disconnect fuel high-pressure tube (3) and

injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector wir-
ing harness on the injector side and the
bracket on the rocker housing side and
r e mo v e t he i n j ec to r w i r i ng h a r n es s
(Loosen the 2 terminal nuts alternately) 6. Set the engine in the no-injection cranking
from the injector. mode. For details, see “No-injection cranking”
a Pass injector under the fuel path projected in the Special function of machine monitor.
sideways and pull up the injector through k If the engine is not set in the no-injec-
wire (Do not pry the injector top up). tion cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
PC2000-8 13
7. Rotate the engine with the starting motor and a Install the injector wiring harness accord-
measure the compression pressure. ing to the following procedure.
a Read the pressure gauge pointer when it 1) Install the injector wiring harness to the
is stabilized. cylinder head and fix the connector side
with the plate. Install O-ring (16).
8. After finishing testing, remove the testing tools 2) Install cap (17) with clip on the injector
and return the removed parts. side of wiring harness.
a Install the injector and fuel high-pressure Press wiring harness (18) between the
tube according to the following procedure. injector top and cap to the injector main
1) Push in injector (11) with the hand to body without slack.
assemble holder (12) temporarily. 3) Tighten nut (19) on the injector side.
2) Tighten bolt (13) and washer (14) tempo- 3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
rarily.
2 Spherical part of washer:
Engine oil
3) Tighten sleeve nut (15) of the fuel high-
pressure tube temporarily.
4) Tighten bolt (13) permanently.
3 Bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
5) Tighten sleeve nut (15) permanently.
3 Sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}
4) Tighten the clamp and spacer with the

bolt.
5) Install rocker arm assembly.
3 Rocker arm assembly mounting
bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust the valve clearance. For details,
see “Adjusting valve clearance”.
6) Install head cover.
3 Cylinder head cover mounting bolt:
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
14 PC2000-8
Testing blow-by pressure 1
a Testing tool for blow-by pressure

Symbol Part No. Part name Q'ty
E 1 799-201-1504 Gauge 1
a Measure blow-by pressure after the engine is

warmed up.
q Hydraulic oil temperature: 45 – 55°C
q Engine coolant temperature: Min. 70°C
1. Equipped blow-by pressure sensor for VHMS

control system.
5. Run the engine at the rated output (P mode
The blow-by signal can be checked by moni-
and relieve the boom raise) and test the blow-
toring function equipped machine monitor.
by pressure.
q Monitoring code: 42800 blow by pressure
a Operation procedure is referred to the “Special
functions of machine monitor”.
a Monitor indication is absolute pressure.
2. If the testing tools are used, check procedure

is as follows.
a Breather is provided to each RH and LH

banks. Test the breather on either one of the
banks.
3. Install adapter [2] and nozzle [3] to the tip of

each breather hose on the RH and LH.
a If rated output is not possible, measure the
4. Connect tube [4] and gauge [1] to either one of
blow-by in high-idle operation.
the nozzles. Close the tube connecting mate of
In this case, approx. 80% of blow-by pressure
other nozzle with a piece of short cut tube, etc.
of the rated output can be obtained.
a Since blow-by pressure varies sharply depend-
ing on engine condition, if measured value is
judged abnormal, investigate phenomena
associated with defective blow-by such as
large oil consumption, abnormal exhaust color,
oil degradation and earlier contamination, etc.

and return the removed parts.
PC2000-8 15
Testing engine oil pressure 1 2) Install nipples [1] and [2] of hydraulic tester
F1 and connect them to hydraulic tester
F2.
a Testing tools for oil pressure a Since the screw size of the sensor
Symbol Part No. Part name mount is 14 x P1.5, nipple (799-101-
5230) may be used.
799-101-5002 Hydraulic tester
1 3) Run the engine at the rated output (P
F 790-261-1204 Digital hydraulic tester mode and boom raise relief) and low idle
2 799-401-2320 Hydraulic tester and test the oil pressure.
1. Equipped engine oil pressure sensor.

The engine oil pressure signal can be checked by
monitoring function equipped machine monitor.
q Monitoring code:
37200 engine oil pressure sensor
a Operation is referred to the “Special func-
tions of machine monitor”.
2. If the testing tool are used, check procedure is

as follows.
1) Remove plug (1) (14 x P1.5) on the LH
side of the cylinder block.
4) After finishing testing, remove the testing

tools and return the removed parts.
16 PC2000-8
Handling fuel system parts 1 Releasing residual pressure in

fuel system 1
a Precautions for testing and maintaining fuel
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. sticks a The pressure in both low-pressure circuit and
to any part, wash that part thoroughly with high-pressure circuit lowers to a safety level
clean fuel. automatically 30 seconds after the engine is
a Precautions for replacement of fuel filter car- stopped.
tridge a Before the fuel circuit is tested and its parts are
The fuel filter cartridge used must be a genuine removed, the residual pressure in the fuel cir-
Komatsu part. cuit must be released completely. Accordingly,
The fuel injection pump and nozzle of the com- observe the following.
mon rail type fuel injection system (CRI) are k Before testing the fuel system or removing
consisted of more precision parts than those its parts, wait at least 30 seconds after stop-
used for the current pumps and nozzles. This ping the engine until the residual pressure
system, therefore, employs a special filter with in the fuel circuit is released. (Do not start
highly efficient filtering performance to prevent the work just after stopping the engine
mixing of foreign substances. Thus, substitut- since there is residual pressure.)
ing it with a non-genuine filter could cause
troubles in the fuel system. It is strictly prohib-
ited to use such part.
PC2000-8 17
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a If the fuel pressure is in the following
a Testing tools for fuel pressure range, it is normal.
Symbol Part No. Part name Engine speed Fuel pressure
799-101-5002 Hydraulic tester 0.15 – 0.3 MPa
1 High idle
790-261-1204 Digital hydraulic tester {1.5 – 3 kg/cm2}
2 795-471-1450 Adapter
G
799-101-5220 Nipple
3
07002-11023 O-ring
4 799-401-2320 Gauge
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the engine
controller cooler and fuel filter to the supply
pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove air bleeder plug (1) on the top of fuel

filter. 4. Since the fuel circuits on the LH and RH banks
after the priming pump are independent, test
each circuit.

and return the removed parts.
2. Install adapter [G2] and connect to gauge [G4].
18 PC2000-8
Testing leakage from pressure limiter and return rate from injector 1
Type of engine having intake manifold equipped with return block
a If the engine is of a type that returns the fuel a Prepare an oil pan of about 20 l to receive the
spilling from the injector from the return block fuel flowing out during the test.
installed to the front of intake manifold, check
the engine according to the following. 1. Preparatory work (case of the LH bank)
a Testing tools for pressure limiter leakage and 1) Remove tube (4) between common rail (3)
injector return rate and supply pump (5).
2) Insert spacer H1 on supply pump (5) side
and tighten the removed joint bolt again.
1 6151-51-8490 Spacer 3) Connect the return piping to the fuel tank
2 6141-71-1710 Joint side again.
Commercially Hose (Inside diameter: a Make sure to install gaskets on both
3 ends of spacer.
available Approx. 11 mm)
Commercially Hose (Inside diameter:
4
H available Approx. 17 mm)
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
7 07376-70315 Plug
PC2000-8 19
a If the leakage from the pressure lim-

iter is in the following range, it is nor-
mal.
Engine speed Leakage
(rpm) (cc/min)
1,600 Max. 10
4) Insert joint H2 on common rail (3) side and

tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the joint.
5) Connect test hose H3 to the end of joint
H2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off. 5) After finishing testing, stop the engine.
a The above is the preparation work for
testing the leakage from the pressure
limiter. 3. Testing return rate from injector
a Keep the hose on the pressure limiter side
connected and keep its end in the oil pan
while testing the return rate from the injec-
tor.
1) Disconnect return hose (2) of return block
(1) and connect test hose H4.
a Apply plug H7 to the return hose side
to stop oil, and fix it to the fuel tank.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
2) Lay test hose H4 so that it will not slacken
and put its end in the oil pan.
2. Testing leakage from pressure limiter

1) Lay test hose H3 so that it will not slacken
and put its end in the oil pan.
2) Operate the machine monitor and set it so
that it can check the engine speed.
3) Start the engine and keep its speed to
1,600 rpm with no load.
4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
20 PC2000-8
3) Operate the machine monitor and set it so

that it can check the engine speed.
4) Run the engine at the rated output (With P
mode and boom raise relieved).
5) After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Limit of return rate (spill)
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
6) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
5. Check the RH bank following the identical pro-

cedure.
PC2000-8 21
Bleeding air from fuel circuit 1 2) Set a container to receive oil under the
fuel prefilter cartridge.
3) Remove the drain hose (4) of cup (3) of
a If fuel is used up or if a fuel circuit part is the water separator.
removed and installed, bleed air from the fuel 4) Using the filter wrench, turn filter cartridge
circuit according to the following procedure. (2) to the left to remove.
5) Turn cup (3) of the water separator
Reference installed to the bottom of the removed car-
q The Komatsu genuine fuel filter cartridge tridge to the left to remove. (This cup will
employs a high-efficiency special filter. Always be reused.)
use it. 6) Install removed cup (3) to the new fuel
q The common rail fuel injection system used on prefilter cartridge. (At this time, be sure to
this machine consists of more precise parts use a new O-ring.)
than the conventional fuel injection pump and 3 Cup: 10 Nm {1.0 kgm}
nozzle. If a filter cartridge other than the
Komatsu genuine one is used, foreign matter
may enter the fuel system and may cause a
trouble in the system. Accordingly, never use a
substitute.
q When checking or servicing the fuel system,
take care of entry of foreign matter more than
ever. If dirt sticks, wash it off with fuel.
1. Replacing prefilter cartridge or bleeding air

from it
1) Pull fuel shut-off lever (1) installed to the
front of the main pump in the pump room
to close the fuel supply circuit from the fuel
tank.
22 PC2000-8
7) Clean the filter stand. Fill the new or 12) Press down fuel cut lever (1) installed to
reused filter cartridge with clean fuel, the front of the main pump in the pump
apply oil to the packing surfaces thinly, room to supply the fuel.
and install the cartridge to the filter stand.
a Add fuel through 8 small holes (a) on
the dirty side without removing cap
(b) at the center.
a After adding fuel, remove cap (b) at
the center and install the fuel filter.
a Fill the fuel filter with clean fuel and
take care that dirt will not enter it.
Since the center is the clean side, do
not remove cap (b) when adding fuel,
and particularly take care that dirt will
not enter it.
8) When installing the filter cartridge, tighten

it 3/4 turns after its packing surface
13) Start the engine and check the filter seal
touches the seal surface of the filter stand.
surface and water separator mounting
a If the filter cartridge is tightened too
surface for fuel leakage and then run the
much, fuel will leak because of dam-
engine at low idle for about 10 minutes.
age of the packing. If the filter car-
tridge is not tightened sufficiently, fuel
will also leak through the clearance of
the packing. Accordingly, observe the
tightening angle.
q When tightening the filter car-
tridge with the filter wrench, take
care extremely not to scratch or
dent the filter.
9) Install the drain hose.
10) Check that the drain plug at the cup bot-
tom of the water separator is tightened
securely.
3 Drain plug:
0.2 – 0.45 Nm {0.02 – 0.046 kgm}
11) When replacing the standard fuel filter car-
tridge (every 1,000 hours) or bleed air
from it, see “Replacing main filter car-
tridge”.
PC2000-8 23
2. Replacing main filter cartridge or bleeding

air from it
1) Replacing main filter cartridge
1] Pull fuel shut-off lever (1) installed to
the front of the main pump in the
pump room to close the fuel supply
circuit from the fuel tank.
a Do not add fuel to the fuel filter car-

tridge.
a Remove cap (b) at the center and
install the fuel filter.
5] When installing the filter cartridge,

tighten it 3/4 turns after its packing
2] Set a container to receive oil under surface touches the seal surface of
the filter cartridge. the filter stand.
3] Using the filter wrench, turn filter car- If the filter cartridge is tightened too
tridge (5) to the left to remove. much, fuel will leak because of dam-
4] Clean the filter stand. Thinly apply oil age of the packing. If the filter car-
to the packing of the new filter cartridge is not tightened sufficiently, fuel
tridge and install the cartridge to the will also leak through the clearance of
filter stand. the packing. Accordingly, observe the
tightening angle.
q When tightening the filter car-
tridge with the filter wrench, take
care extremely not to scratch or
dent the filter.
6] After replacing filter cartridge (5),
loosen its air bleeding plug (6) and
press down fuel shut-off lever (1) to
open the fuel supply circuit from the
fuel tank.
a Open the circuit in the reverse
order to closing.
24 PC2000-8
2) To bleed air when fuel is used up, perform 3) Bleed air according to the following proce-
the following air bleeding procedure taken dure.
after replacement of the main filter car- 1] Fill the fuel tank with fuel (to the FULL
tridge. mark of the fuel level gauge).
2] After replacing filter cartridge (5),
loosen air bleeding plug (6).
3] Remove locknut (8) of priming pump
lever (7), operate priming pump lever
(7), and check that fuel and bubbles
flow out of air bleeding plug (6).
4] Tighten air bleeding plug (6).
3 Plug:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
5] Push in priming pump lever (7) and
tighten locknut (8) to lock it.
6] After replacing the filter cartridge,
start the engine and check the filter
seal surface for fuel leakage.
PC2000-8 25
Bleeding air from fuel circuit (low- 3. Shift switch (2) for the electric priming pump in
grade fuel specification) 1 the power container to ON position.
a Lamp (3) will start flashing and operation
of the electr ic priming pump will be
a Bleed air according to this procedure in the fol- started.
lowing cases.
q When the fuel filter was replaced
q When fuel ran out
q When starting the engine for the first time
after replacing the fuel piping or supply
pump
a When replaced the fuel filter, don't feed fuel to
the filters, including both the main and pre-fil-
ter.
k Pressure is constantly applied to the fuel

circuit as long as operation of the electric
priming pump is continued. Loosening the
air bleeding plug from this state might
allow fuel to burst out. Thus, don't try to a The built-in timer of this switch automati-
loosen the plug while the pump is in opera- cally starts or stops operation of the elec-
tion. tric priming pump. (See the figure below)
a Operation of the electric priming pump is
1. Set the starting switch to OFF position. stopped as long as flashing of the lamp is
continued. It is not an error.
2. Open the air bleeding valves (1) (one for each a Shifting the switch to "OFF" while the lamp
side). is flashing turns off the lamp and stops the
a Place the valves horizontally. electric priming pump, too.
q Left bank
4. As the specified duration (about 6.5 minutes) is

expired, lamp (3) automatically goes off, stop-
q Right bank ping the electric priming pump.
a When the fuel filter alone was replaced,
above completes bleeding air.
5. When fuel is not provided in the fuel circuit

such as when run out of fuel occurred or when
replacement of the fuel pipe or supply pump
was done, set switch (2) to "ON" again after
the electric priming pump is automatically
stopped.
6. Bleeding air, in this case, completes as lamp

(3) went off.
26 PC2000-8
7. Close the air bleeding valves (1).

a Place the valves vertically.
q Left bank
q Right bank
8. Crank the engine using the starting motor and

start the engine.
a By cranking the engine, air in the high-
pressure circuit bleeds out automatically.
a If the engine does not start, inappropriate
bleeding air in the low-pressure circuit
may be suspected. In this case, perform
the followings:
1) Shift the electric priming pump switch to
ON position.
2) Start the engine while the electric priming
pump is operating.
a If the engine does not start, repeat
this.
3) After the engine starts, let the engine run
for more than 5 minutes to bleed air com-
pletely from the fuel circuit.
PC2000-8 27
Testing fuel system for leakage 1 a If any fuel leakage is detected, repair it
and inspect again from step 1.
a If no fuel leakage is detected, check is
k Very high pressure is generated in the high- completed.
pressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dan-
gerous since it can catch fire.
After testing the fuel system or removing
its parts, test it for fuel leakage according
to the following procedure.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
4. Run the engine at low idle.

leakage.
for fuel leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
8. Run the engine at high idle.

a Relieve the hydraulic pump.

leakage.
for fuel leakage.
28 PC2000-8
Testing and adjusting Adjustment

a Adjust the belt according to the following pro-
alternator belt tension cedure when the belt deflection is not normal.
Testing 1. Loosen nuts and bolts (1), (2), (3) and (4) in
1. Remove V belt cover (7) on the rear side of the this order.
engine.
2. Turn nut (5) to move alternator (6), and adjust
the belt tension.
a Nut (5):
q It is moved to the side that belt is
loosened when fastening it clockwise.
q It is moved to the side that belt is ten-
sioned when loosening it counter-
clockwise.
a Test for breakage of each pulley, friction of
V-ditch, friction of belt, and contact
between belt and V-ditch.
a Replace it with new belt if it was too
stretched so that adjustability was lost, or
cut and crack occurred.
2. Measure the belt deflection (a) when pushing a
point midway between the alternator pulley 3. Tighten nuts and bolts (4), (3), (2) and (1) in
and the drive pulley with the finger. this order.
a Deflection (a) when pressing force is a When the belt was replaced, readjust it
approx. 58.8 N {approx. 6 kg}: 10 – 15 mm after one-hour operation.
PC2000-8 29
Testing and adjusting air Adjustment procedure

conditioner compressor belt a Adjust the belt according to the following pro-
tension 1 cedure when the amount of belt deflection is
not normal.
Testing procedure 1. Loosen nuts and bolts (1), (2), (3) and (4) in
1. Dismount belt covers (7) and (8). this order.
2. Turn nut (5) to move air conditioner compres-

sor (6), and adjust the belt tension.
a Nut (5):
q It is moved to the side that belt is
loosen when fastening it clockwise.
q It is moved to the side that belt is ten-
sioned when loosening it counter-
clockwise.
a Test for breakage of each pulley, friction of
V-ditch, friction of belt, and contact
between belt and V-ditch.
a Replace it with new belt if it was too
stretched so that adjustability was lost, or
cut and crack occurred.
3. Tighten nuts and bolts (4), (3), (2) and (1) in

this order.
2. Measure the belt deflection (a) when pushing a

point midway between the air conditioner com-
pressor pulley and the drive pulley with the fin-
ger.
a Press force at approx. 58.8 N {Approx. 6
kg}, (a): 6 mm
4. Mount the belt cover.
30 PC2000-8
SEN02007-00
© 2006 KOMATSU
All Rights Reserved
32
SEN02008-00
PC2000-8

PC2000-8 20001 and up

Testing swing circle bearing clearance................................................................................................. 3
Remaining pressure relief from HIC circuit .......................................................................................... 4
Gas filling in HIC circuit accumulator ................................................................................................... 4
Bleeding air from HIC circuit and supplying oil to it.............................................................................. 6
Testing and adjusting track shoe tension ............................................................................................. 8
Testing and adjusting work equipment, swing and travel circuit oil pressures ....................................11
Testing and adjusting control circuit oil pressure (output pressure of self pressure reducing valve) . 15
Testing and adjusting main pump control signal ................................................................................ 17
Measuring fan speed.......................................................................................................................... 20
Measuring fan pump EPC solenoid current ....................................................................................... 21
Measuring fan pump EPC solenoid valve output pressure ................................................................ 22
Oil pressure measuring points for pump discharge pressure or jet sensor differential pressure ....... 24
Measuring PPC valve output pressure............................................................................................... 25
Measuring solenoid valve outlet pressure.......................................................................................... 30
Adjusting work equipment and swing PPC valve ............................................................................... 32
PC2000-8 1
Testing and adjusting travel deviation ................................................................................................ 33

Testing work equipment hydraulic drift cause portion......................................................................... 35
Testing oil leakage.............................................................................................................................. 36
Remaining pressure relief from hydraulic circuit ................................................................................ 39
Air bleeding from each component..................................................................................................... 40
Air bleeding from PPC circuit ............................................................................................................. 45
Testing and adjusting auto grease system ......................................................................................... 47
Adjusting mirrors ................................................................................................................................ 50
2 PC2000-8

Testing swing circle bearing 3. Set the dial gauge K to the zero point.
clearance 1
4. Arrange the arm almost at right angles to the
ground and lower the boom until the front leg
a Inspection device of swing circle bearing clear- of the machine body rises.
ance a At the time, the front of the upper structure
Symbol Part Number Part Name rises and its rear lowers.
Dial gauge
K Commercial item
(with magnet)
a When measuring swing circle bearing clear-

ance on a machine, follow the procedures
below:
1. Fix the dial gauge K to the track frame (center
frame) and bring the stylus to the outer race
end face.
a Set the dial gauge to the front or to the
rear.
5. At the time, read the value on the dial gauge K.

This value on the dial gauge indicates the
swing circle bearing clearance.
k During the measurement, never place
hands and legs below the undercar-
riage.
6. Return the work equipment to the state in

Paragraph 2 and make sure that the dial gauge
K has returned to the zero point. If not, repeat
Steps 3 to 5.
2. Set the work equipment to the maximum reach
and set the bucket tip to the height of the
revolving frame lower face.
a At the time, the front of the upper structure
lowers and its rear rises.
PC2000-8 3
Remaining pressure relief from Gas filling in HIC circuit

HIC circuit 1 accumulator 1
a If the HIC equipment is to be removed or the a Device for filling gas in HIC circuit accumulator
piping are to be disconnected, release the
Symbol Part Number Part Name
remaining pressure from the HIC circuit as fol-
lows. Charge valve
M 792-610-1700
k
assembly
Lower the work equipment completely to
the ground, stop the engine and use the
control lever several times to relieve pres- a If the gas was discharged from the HIC circuit
sure remaining in the pipe. Then, loosen accumulator or the accumulator was replaced,
the oil filler cap of the hydraulic tank gradu- charge the accumulator with gas according to
ally to relieve pressure in the tank. the following procedure.
1. Loosen stop valves (1) and (2) slowly and 1. Relieve pressure remaining in the HIC circuit.
relieve pressure remaining in the circuit. a Refer to the Paragraph of “Remaining
k Quick loosening will cause a high pres- pressure relief from HIC circuit” and leave
sure in the tank circuit, so be sure to 2 pieces of the stop valve loosened.
loosen the stop valves slowly.
a After 1 minute elapsed, the remaining gas 2. Attach the plug (1) to the accumulator.
will have been relieved completely.
3. Attach the valve kit [1] of the charge valve

assembly M to accumulator (2) and attach the
nipple [2] to nitrogen bomb (3). Then, connect
the valve kit [1] and the nipple [2] with the hose
[3].
a Before attaching the valve kit [1], turn the
valve [4] fully to the left and turn the valve
[5] to the left and keep it opened.
2. When the remaining pressure is relieved com-

pletely, retighten stop valves (1) and (2).
4 PC2000-8
4. Open the valve [7] of the nitrogen bomb (3)

slowly, keep the pressure to the pressure
gauge [6] at 0.2 – 0.3 MPa {2 – 3 kg/cm2} and
tighten the valve [5].
k Quick filling high pressure gas will
expand the plug suddenly and may
break it, so be sure to fill nitrogen gas
slowly.
5. Screw in the valve [4] until it touches some-

thing lightly.
6. Open the valve [7] further slowly and fill the

accumulator (4) with nitrogen gas.
a Close the valve [7] gradually until the
pressure gauge becomes stable, and then
read the value shown on the pressure
gauge.
7. After filling nitrogen gas to the specified pres-

sure, tighten the valve [7] firmly.
a Specified pressure :
13.2 ± 0.3 MPa {135 ± 3 kg/cm2}
(Atmospheric temperature: 20 ± 3°C)
a If more pressure than the specified one
was filled in, tighten the valve [7] and turn
the valve [4] slowly to the left to relieve the
gas gradually to the specified pressure.
8. Turn the valve [4] to the left until it stops, turn

the valve [5] to open it and discharge gas
remaining in the valve kit [1] and the hose [3].
9. Remove the valve kit [1] from accumulator (2)

and attach plug (3) to the valve kit.
10. After filling gas, bleed air from the HIC circuit
and fill pressurized oil in the circuit.
a Refer to the paragraph of “Bleeding air
from HIC circuit and supplying oil to it”.
PC2000-8 5
Bleeding air from HIC circuit and 3. Fully open stop valve (3) at the inside of the
supplying oil to it 1 axle.
Before bleeding air from the HIC circuit and supply-

ing grease to the hydraulic grease supply cylinder,
be sure to bleed air.
1. Loosen plug (1) of the grease cylinder by 1

turn (2 places on the right and left).
2. Fully open stop valve (2) at the inside of the

axle.
4. Loosen air bleeding plug (4) of the cushion cyl-

inder about 1 turn (2 places on the right and
left).
6 PC2000-8
5. Remove plug (6) under the block on the side of

the relief valve and loosen air bleeding plug (5)
about 1 turn.
8. Tighten plugs (1) (at 2 places on the right and

left).
9. Tighten plug (6).

3 Plug: 81.3 ± 6.9 Nm {8.3 ± 0.7 kgm}
a Be sure to tighten plug (1) last.
a Fully close the stop valves and air bleed-
ing plugs.
a After bleeding air, test and adjust the track
shoe tension. For details, see “Testing and
adjusting track shoe tension”.
6. Run the engine at low idle for 2 – 3 minutes.
7. When clear oil flows out of air bleeding plugs

(4) (at 2 places on the right and left) and the
hole for plug (6) under the block on the side of
the relief valve, fully tighten valves (2) and (3)
and plugs (4) and (5).
PC2000-8 7
Testing and adjusting track shoe Adjusting

tension 1 a If the track shoe tension is abnormal, adjust it
according to the following procedure.
Testing 1. Adjusting HIC cylinder

1. Run the engine at low idle and drive the 1) Check that stop valve (4) at the inside of
machine forward by the length of track on the axle is fully closed.
ground, and then stop slowly.
2. Place steel bar (b) on the track shoe between

2nd carrier roller (1) and 3rd carrier roller (2).
3. Measure the maximum clearance between the

track shoe top and the steel bar.
q Maximum clearance (a): 10 – 30 mm
8 PC2000-8
2) Open stop valve (5) at the inside of the

axle.
7) Fully close stop valve (4).
2. Adjusting grease cylinder
When tension is low

1) Add grease through plug (8).
2) To check that the tension is normal, move
the machine forward slowly.
3) Check the track shoe tension again. If it is
not proper, adjust it again.
3) Turn the fuel control dial to the medium

position and run the engine at medium
speed.
4) Operate the right travel lever in the for-
ward and reverse directions intermittently
(2 – 3 seconds) 5 – 6 times.
a Do not perform this operation on a
slippery place (steel plate etc.)
a Even if projection (a) of the hydraulic
cushion cylinder is normal, the
hydraulic cushion charge pressure
may be low. Accordingly, perform the
operation in 4) securely.
5) Check that projection (a) of the plunger of
hydraulic cushion cylinder (7) is 135 ± 5
mm on each side.
6) If projection (a) is not 135 ± 5 mm, perform
the operation in 4) again to set projection
(a) in the specified range.
If projection (a) cannot be set to 135 ± 5
mm, too much grease may be in grease
cylinder (6). In this case, discharge the
grease according to “2. Adjusting grease
cylinder”.
PC2000-8 9
4) You may adjust the track shoe tension by

adding grease until projection (b) of
grease cylinder (9) becomes 35 – 190
mm.
a If the tension is still low, the pins and
bushings may be worn much.
When tension is too high

1) Loosen plug (8) gradually to discharge
grease.
k Do not loosen the valve more than
1 turn. If it is loosened more, it may
jump out because of the high-pres-
sure grease in it.
k If the grease is not discharged
well, move the machine forward
and in reverse and then check the
track shoe tension.
2) Tighten plug (8).
3) To check that the tension is normal, move
the machine forward and in reverse.
4) Check the track shoe tension again. If it is
not proper, adjust it again.
10 PC2000-8
Testing and adjusting work 2) Measurement of relief oil pressure at the

equipment, swing and travel time of heavy lift operation
a
circuit oil pressures 1 i) Start the engine and turn on the
heavy lift switch.
Measurement ii) Measure the oil pressure when the
a Measure the work equipment, swing and travel boom cylinder is raised and is
circuit oil pressures under the following condi- relieved individually at the stroke end
tions: at high idle.
q Hydraulic oil temperature : 45 – 55ºC a The heavy lift function works only
when the boom is individually raised.
1. Preparatory work a The main relief valve of each control
Turn on the starting switch and display the valve is relieved on the high pressure
screen for measuring the work equipment, set side.
swing and travel circuit oil pressures on the 3) Measurement of relief oil pressure at the
machine monitor. time of machine push operation
a For the control method, refer to the para- i) Start the engine and turn on the
graph of “Special function of machine machine push-up switch.
monitor”. ii) Measure the oil pressure when the
a Screen display on the machine monitor boom cylinder is lowered and is
(Display unit : MPa, kg/cm2) relieved individually at the stroke end
q Monitoring code: at high idle.
01124 P1F pump pressure a When the boom cylinder is lowered
01125 P1R pump pressure and relieved at the stroke end, the
01126 P2F pump pressure safety valve with suction on the boom
01127 P2R pump pressure lower side of the control valves VL1
and VR2 is relieved (because the set
pressure is lower than that of the
main relief valve).
3. Measurement of swing oil pressure

1) Start the engine and turn on the swing lock
switch.
2) Measure the oil pressure when the swing
motor is relived at engine high idle.
a The safety valve of the swing motor is
relieved.
4. Measurement of travel oil pressure

1) Start the engine and place a pin or a block
between the sprocket and the track frame
2. Measurement of work equipment oil pres- or the track link to lock traveling.
sure k Make sure that travel is certainly
1) Measurement of normal relief oil pressure locked.
Start the engine and measure the oil pres- 2) Measure the oil pressure when the travel
sure when each cylinder is relieved individ- motor is relieved at engine high idle.
ually at the stroke end at high idle. a The main relief valve of each control
a The main relief valve of each control valve is relieved on the high pressure
valve is relieved on the low pressure set side.
set side.
a When the boom cylinder is lowered
and relieved at the stroke end, the
safety valve with suction on the boom
lower side of the control valves VL1
and VR2 is relieved (because the set
pressure is lower than that of the
main relief valve).
PC2000-8 11
Adjustment 1) Loosen the locknut (5) and make the

1. Adjustment of main relief valve (High pres- elbow (6) free.
sure set) of control valves VL1, VL2, VR1 2) Loosen the locknut (7) and turn the holder
and VR2 (8) for adjustment.
a When the work equipment oil pressure q Turn the holder to the right, and the
(when the machine push-up is working) is pressure will rise.
abnormal or when the travel oil pressure is q Turn the holder to the left, and the
abnormal, adjust the high pressure set pressure will lower.
side of the main relief valves (1), (2), (3) a Pressure adjusted by a turn of the
and (4) of each control valve according to holder: about 21.8 MPa {222 kg/cm2}
the following procedures: 3 Locknut (7) :
q (1) : VL1 control valve (P1R pump) 93 – 123 Nm {9.5 – 12.5 kgm}
q (2) : VL2 control valve (P2R pump) a Since the low pressure set changes
q (3) : VR1 control valve (P1F pump) when the high pressure set is
q (4) : VR2 control valve (P2F pump) adjusted, the low pressure set should
be adjusted.
q VL valve
3) Fix the elbow (6) and tighten the locknut
(5).
q VR valve
4) After the adjustment, check the oil pres-

sure again according to the above mea-
surement procedures.
a High pressure set is the state that the 2-

stage relief solenoid valve is ON and that
a pilot pressure is applied to the
changeover port.
12 PC2000-8
2. Adjustment of main relief valve (Low pres- 3. Adjustment of swing motor safety valve
sure set) of control valves VL1, VL2, VR1 a When the swing oil pressure is abnormal,
and VR2 adjust the swing motor safety valves (11)
a When the work equipment relief oil pres- and (12) according to the following proce-
sure (normal relief) is abnormal, adjust the dures:
low pressure set side of the main relief q (11) : For the front swing motor
valves (1), (2), (3) and (4) of each control q (12) : For the rear swing motor
valve according to the following proce-
dures:
a Low pressure set is the state that the 2-
stage relief solenoid valve is OFF and that
a pilot pressure is not applied to the
changeover port.
1) Loosen the locknut (5) and make the
elbow (6) free.
2) Loosen the locknut (9) and turn the holder
(10) for adjustment.
q Turn the holder to the right, and the
pressure will rise.
q Turn the holder to the left, and the
pressure will lower.
a Pressure adjusted by a turn of the
holder: about 21.8 MPa {222 kg/cm2}
3 Locknut (9) :
78 – 93 Nm {8.0 – 9.5 kgm}
3) Fix the elbow (6) and tighten the locknut

(5).
a The front and rear swing motors are

divided from one spool. Adjust the valves
in the following procedures.
a If swing starting power is not powerful, or if
swing speed is not fast:
1) Put match marks on the body and on
adjustment screw (14) for safety valves
(11) and (12) of each motor.
4) After the adjustment, check the oil pres- a The match marks are for returning the
sure again according to the above mea- screw and body to the original posi-
surement procedures. tions after no fault is found.
2) Loosen locknut (14) of safety valve on one
side and tighten adjustment screw (13).
q Turn the adjustment screw to the
right, and the pressure will rise.
q Turn the adjustment screw to the left,
and the pressure will lower.
a Pressure adjusted by one turn of the
adjustment screw :
about 4.70 MPa {47.9 kg/cm2}
3 Locknut :
147 – 196 Nm {15 – 20 kgm}
PC2000-8 13
3) Start the engine, relieve the swing lock,

and measure the relief oil pressure.
4) Rise of the oil pressure shows lowering of
the valve set pressure. Adjust the pres-
sure according to the criteria.
5) If the oil pressure is not changed, return
the valves to the original positions in
accordance with the match marks.
6) Adjust the relief valves on the other side in
the same steps 2) – 4) above.
7) After the adjustment, check the oil pres-

sure again according to the above mea-
surement procedures.
14 PC2000-8
Testing and adjusting control 3. Run the engine at high idle, set the work equip-
circuit oil pressure (output ment/swing lever and travel lever in neutral,
and measure the oil pressure.
pressure of self pressure
reducing valve) 1
a Instruments for testing and adjusting control

circuit oil pressure
1
790-261-1204 Digital hydraulic tester
P
799-101-5220 Nipple (10 x 1.5 mm)
2
07002-11023 O-ring
Measuring
a Measure the control circuit oil pressure under
the following condition. Adjusting
q Hydraulic oil temperature: 45 – 55°C a If output pressure of self pressure reducing
k Lower the work equipment to the valve is not normal, adjust self pressure reduc-
ground and stop the engine. Operate ing valve (2) in the following procedure.
the control levers several times to
release the residual pressure in the
piping, and then loosen the oil filler cap
of the hydraulic tank slowly to release
the internal pressure of the hydraulic
tank.
1. Remove pressure measurement plug (1) of the

main pump.
a The plugs are installed in the same places
for P1 and P2 pumps.
2. Install nipple P2 and connect oil pressure

gauge [1] of hydraulic tester P1.
1) Fix adjustment screw (3) and then loosen

locknut (4).
2) Adjust the pressure by turning adjustment
screw (3).
a Target values: 3.2 – 3.5 MPa {33 – 36
kg/cm2}
a Adjustment screw:
q Turning it clockwise increases
the pressure.
q Turning it counterclockwise
decreases the pressure.
a Pressure adjusted by one turn of the
adjustment screw: 1.16 MPa {11.9 kg/
cm2}
PC2000-8 15
3) Fix adjustment screw (3) and then tighten

locknut (4).
3 Locknut :
59 – 78 Nm {6 – 8 kgm}
16 PC2000-8
Testing and adjusting main pump 2) Install nipple Q2 and connect oil pressure
control signal 1 gauge [1] of hydraulic tester Q1.
a Use the oil pressure gauges of 5.9
MPa {60 kg/cm2}.
a Devices for inspecting and measuring main
pump control signal
1
Q
799-101-5220 Nipple (10 × 1.5 mm)
2
07002-11023 O-ring
Measurement
a Measure the piston pump control oil pressure
under the following conditions:
k Lower the work equipment to the ground
and stop the engine. Operate the control 3) Start the engine and set the working mode
levers several times to release the residual switch in the P-mode position.
pressure in the piping, and then loosen the 4) Set all the control levers in neutral and
oil filler cap of the hydraulic tank slowly to measure the EPC solenoid valve output
release the internal pressure of the hydrau- pressure under the following condition.
lic tank. i) Set all the control levers in neutral.
ii) Run the engine at high idle and
1. Measuring EPC solenoid valve output pres- measure the output pressure.
sure 5) Drive the travel motor idle and measure
a Since the basic pressure of the EPC sole- the EPC solenoid valve output pressure
noid valve is the control circuit pressure, under the following condition.
check that the control circuit pressure (self i) Raise the track shoe to be measured
pressure reducing valve) is normal before by using the boom and arm
measuring the EPC solenoid valve output ii) Run the engine at high idle, drive the
pressure. travel motor idle and measure the
a The EPC solenoid valve is controlled with output pressure.
the command current from the pump con- a For measurement posture, see “Stan-
troller. (For details, see Structure, function dard service value table”.
and maintenance standard.)
1) Remove oil pressure pickup plug (1) or 2. Measuring EPC solenoid valve current
(2). a The EPC current can be checked with the
a Plug (1) is on the front pump side and monitoring function of the machine moni-
plug (2) is on the rear pump side. tor, too.
a The plugs are installed in the same (For the operating method, see “Special
places for P1 and P2 pumps. functions of machine monitor”.)
q Monitoring code:
01306 P1F pump EPC current
01308 P1R pump EPC current
01310 P2F pump EPC current
01312 P2R pump EPC current
1) Start the engine and set the working mode
switch in the P-mode position.
2) Set all the control levers in neutral and
measure the EPC current under the fol-
lowing condition.
i) Set all the control levers in neutral.
ii) Run the engine at high idle and
measure the current.
PC2000-8 17
3) Drive the travel motor idle and measure 3) Drive the travel motor idle and measure
the EPC current under the following condi- the jet sensor output differential pressure
tion. under the following condition.
i) Raise the track shoe to be measured i) Raise the track shoe to be measured
by using the boom and arm. by using the boom and arm.
ii) Run the engine at high idle, drive the ii) Run the engine at high idle, drive the
travel motor idle and measure the travel motor idle, and measure the out-
current. put differential pressure.
3. Measuring output differential pressure of 4. Measuring output voltage of jet sensor dif-
jet sensor differential pressure sensor ferential pressure sensor
a The jet sensor output differential pressure a The differential pressure sensor output
can be checked with the monitoring func- voltage can be checked with the monitor-
tion of the machine monitor, too. ing function of the machine monitor.
(For the operating method, see “Special (For the operating method, see “Special
functions of machine monitor”.) functions of machine monitor”.)
a Monitoring code: a Monitoring code:
13804 VR1 J/S differential pressure 13808 VR1 J/S differential pressure sensor
13805 VL1 J/S differential pressure voltage
13806 VR2 J/S differential pressure 13809 VL1 J/S differential pressure sensor
13807 VL2 J/S differential pressure voltage
13810 VR2 J/S differential pressure sensor
1) Start the engine and set the working mode voltage
switch in the P-mode position. 13811 VL2 J/S differential pressure sensor
2) Set all the control levers in neutral and voltage
measure the jet sensor output differential 1) Start the engine and set the working mode
pressure under the following condition. switch in the P-mode position.
i) Set all the control levers in neutral. 2) Set all the control levers in neutral and
ii) Run the engine at high idle and meas- measure the voltage under the following
ure the output differential pressure. condition.
i) Set all the control levers in neutral.
ii) Run the engine at high idle and meas-
ure the voltage.
18 PC2000-8
3) Drive the travel motor idle and measure

the voltage under the following condition.
i) Raise the track shoe to be measured
by using the boom and arm.
ii) Run the engine at high idle, drive the
travel motor idle, and measure the
voltage.
1) Fix adjustment screw (21) and loosen

locknut (22).
2) Turn adjustment screw (21) to adjust the
pressure.
a If the adjustment screw is
q turned to the right, the pressure
rises.
q turned to the left, the pressure
Adjusting lowers.
1. Adjusting jet sensors of VR1, VL1, VR2 and a Pressure changed by 1 turn of adjust-
VL2 control valves ment screw: 0.288 MPa {2.94 kg/cm2}
a If the jet sensor output differential pres- 3) Fix adjustment screw (21) and tighten
sure is abnormal, adjust jet sensor relief locknut (22).
valves according to the following proce- 3 Locknut: 59 – 78 Nm {6 – 8 kgm}
dure.
q (17): jet sensor relief valve of VL1 control
valve
q (18): jet sensor relief valve of VL2 control
valve
q (19): jet sensor relief valve of VR1 control
valve
q (20): jet sensor relief valve of VR2 control
valve
4) After finishing adjustment, check the oil

pressure again according to the above
described measurement procedure.
PC2000-8 19
Measuring fan speed 1 2. Measuring fan speed (oil cooler)

1) Open the inspection cover of the engine
hood and remove the fan guard and stick
1. Measuring fan speed (radiator) a reflection tape to the fan (1).
a Tools for measuring fan speed 2) Install the fan guard.
Symbol Part Number Part Name 3) Set probe [1] of multitachometer R with
stand [2], match it to the reflection tape,
R 799-203-8001 Multitachometer
and connect it to meter [3].
a Set the probe with the fan away 100
1) Remove the fan guard and put a sheet of mm from it.
reflection tape (a) on fan (1).
2) Install the fan guard.
3) Set probe [1] of multitachometer R with
stand [2], match it to the reflection tape,
and connect it to meter [3].
a Set the probe with the fan away 100
mm from it.
4) Start the engine, set the fan to 100%

mode, and measure the fan speed with
the engine at high idle.
a Stabilization of the tachometer num-
bers shows correct measurement.
a If the fan is rotated in reverse, the
measuring instruments can be
4) Start the engine, set the fan to 100% sucked in. Accordingly, be sure to
mode, and measure the fan speed with rotate the fan forward when measur-
the engine at high idle. ing.
a Stabilization of the tachometer num-
bers shows correct measurement.
a If the fan is rotated in reverse, the
measuring instruments can be
sucked in. Accordingly, be sure to
rotate the fan forward when measur-
ing.
5) After finishing measurement, remove the

measuring instruments and return the
removed parts.

removed parts.
20 PC2000-8
Measuring fan pump EPC 2. Measuring fan (radiator) pump EPC sole-
solenoid current 1 noid current
a The fan (oil cooler) pump EPC solenoid current
can be checked with the monitoring function of
1. Measuring fan (radiator) pump EPC sole- the machine monitor.
noid current (For the operating method, see “Special func-
a The fan (radiator) pump EPC solenoid current tions of machine monitor”.)
can be checked with the monitoring function of q Monitoring code:
the machine monitor. 31634 O/C fan pump current
(For the operating method, see “Special func- q The current is displayed in mA.
tions of machine monitor”.) a Measure the fan (oil cooler) pump EPC current
q Monitoring code: under the following condition.
31624 RAD fan pump EPC current q Hydraulic oil temperature: 45 – 55°C
q The current is displayed in mA. 1) Run the engine at high idle and measure
the EPC current with the fan 100% speed
a Measure the fan (radiator) pump EPC current mode.
under the following condition.
1) Run the engine at high idle and measure
the EPC current with the fan 100% speed
mode.
PC2000-8 21
Measuring fan pump EPC solenoid 2) Install nipple S2 and connect it to oil pres-
valve output pressure 1 sure gauge [1] of hydraulic tester S1.
q Use the oil pressure gauge of 5.9
MPa {60 kg/cm2}.
a Measuring instruments for fan pump EPC sole- 3) Run the engine at high idle and measure
noid valve output pressure the solenoid output pressure.
Symbol Part Number Part Name 4) After finishing measurement, remove the
799-101-5002 Hydraulic tester removed parts.
1
S
799-101-5220 Nipple (Max. 1.5 mm)
2
07002-11023 O-ring
a Measure the fan pump EPC solenoid valve

output pressure
a Since the basic pressure of the EPC solenoid
valve output pressure is the control circuit
pressure, check that the control circuit pres-
sure is normal before measuring the EPC sole-
noid valve output pressure.
k Lower the work equipment to the ground
and stop the engine. Then, operate the con-
trol levers several times to release the 2. Measuring fan (oil cooler) pump EPC sole-
residual pressure in the piping and loosen noid valve output pressure
the hydraulic tank cap gradually to release 1) Remove oil pressure pickup plug (1) from
the internal pressure of the hydraulic tank. the top of the fan (oil cooler) pump.
1. Measuring fan (radiator) pump EPC sole-

noid valve output pressure
1) Remove oil pressure pickup plug (1) from
the top of the fan (radiator) pump.
2) Install nipple S2 and connect it to oil pres-

sure gauge [1] of hydraulic tester S1.
q Use the oil pressure gauge of 5.9
MPa {60 kg/cm2}.
3) Run the engine at high idle and measure
the solenoid output pressure.
22 PC2000-8

removed parts.
PC2000-8 23
Oil pressure measuring points for (3) Fan (Radiator) pump discharge pressure
pump discharge pressure or jet pickup plug
(4) Fan (Oil cooler) pump discharge pressure
sensor differential pressure 1 pickup plug
a Measuring tools for fan pump discharge
q The oil pressures checked with the monitoring pressure
function can be measured at the following
points with “oil pressure gauges”.
1
1. Measuring main pump discharge pressure 790-261-1204 Digital hydraulic tester
—
(Common to pumps P1 and P2) 799-101-5220 Nipple (M10 x 1.25 mm)
2
07002-11023 O-ring
3. Measuring jet sensor differential pressure

(Common to control valves VL and VR)
(1) Main pump discharge pressure pickup

plug (F pump)
(2) Main pump discharge pressure pickup
plug (R pump)
a Measuring tools for main pump discharge
pressure (5) Jet sensor output pressure (High pressure
Symbol Part Number Part Name side) [Valve 1 side]
(6) Jet sensor output pressure (Low pressure
1 side) [Valve 1 side]
— (7) Jet sensor output pressure (High pressure
799-101-5220 Nipple (M10 x 1.25 mm) side) [Valve 2 side]
2
07002-11023 O-ring (8) Jet sensor output pressure (Low pressure
side) [Valve 2 side]
2. Measuring fan pump discharge pressure a Measuring tools for jet sensor differential pres-
sure
1
Differential pressure
— 2 799-401-2701
gauge
799-101-5220 Nipple (M10 x 1.25 mm)
3
07002-11023 O-ring
24 PC2000-8
Measuring PPC valve output 4. Start the engine, operate the control lever of
pressure 1 the measuring PPC circuit at high idle and
measure the oil pressure.
a When the oil pressure is 0 while the con-
a Devices for measuring PPC valve output pres- trol lever is set at the neutral position,
sure operate the lever to the full stroke. If the oil
pressure comes almost to the oil pressure
of the control circuit, the valve is normal.
1 Digital type hydraulic 5. After the measurement, remove the measuring
790-261-1203
tester devices and return the valve to the original
T 799-401-3200 Adapter assembly #3 state.
2
02896-11009 O-ring
799-401-3300 Adapter assembly #4
3
02896-11012 O-ring
a Measure the PPC valve output pressure under

the following conditions:
q Hydraulic oil temperature : 45 – 55°C
1. Disconnect the hoses (1) – (12) from the PPC

circuit. Check the cab base.
a See the connection drawing in the next
page.
a Disconnect these hoses at the PPC junc-
tion block part.
2. Attach the adapter T2 or T3 and connect the

disconnected hoses again.
a #3 size for the travel and swing circuits.
#4 size for the work equipment circuits.
3. Attach the nipple [1] of the hydraulic tester T1

and connect it to the oil pressure gauge [2].
PC2000-8 25
Measure the pressures inside the cab base first.
No. PPC Circuit Colored band No. PPC Circuit Colored band
1 Boom RAISE Green 7 Swing left Red
2 Boom LOWER Brown 8 Swing right None
3 Bucket CURL White 9 R.H. travel REVERSE Black, black
4 Bucket DUMP Black 10 R.H. travel FORWARD Blue, black
5 Arm OUT Yellow 11 L.H. travel REVERSE Red, black
6 Arm IN Blue 12 L.H. travel FORWARD Green, black
26 PC2000-8
28 PC2000-8
PC2000-8 29
Measuring solenoid valve outlet

pressure 1
a Devices for measuring solenoid valve outlet

pressure
1 Digital type hydraulic
790-261-1203
tester
U 799-401-3200 Adapter assembly
2
02896-11009 O-ring
799-401-3300 Adapter assembly
3
02896-11012 O-ring
a Measure the solenoid valve outlet pressure

under the following conditions:
1. Disconnect the hoses (1) – (11) from the sole-

noid valve circuit to be measured.
2. Attach the adapter U2 and connect the discon-

nected hoses again.
3. Attach the nipple [1] of the hydraulic tester U2

and connect it to the oil pressure gauge [2].
4. Start the engine, idle it at a high speed under

the measuring conditions and measure the oil
pressure.
5. After the measurement, remove the measuring

devices and return the valve to the original
state.
30 PC2000-8
Solenoid Oil pressure

No. Solenoid valve Measuring conditions Machine operation
operation (MPa {kg/cm2})
The back pressure valve
Swing or travel (Back pressure ON) is OFF 0 {0}
Variable back released
1
pressure The back pressure valve
Min. 2.74
All levers at neutral (Back pressure OFF) is ON
{Min. 28}
operated
All levers at neutral — OFF 0 {0}
2 Swing priority Swing priority function is Min. 2.74
Swing and arm or bucket ON
operated. {Min. 28}
When the heavy lift switch is turned The main relief valve is set
OFF 0 {0}
off to low pressure.
3 2-stage relief When the heavy lift switch is turned
The main relief valve is set Min. 2.74
on and boom RAISE is operated ON
to high pressure. {Min. 28}
independently
4 Arm throttle (L1) The arm throttle valve of

Min. 2.74
Boom RAISE and arm IN or OUT control valve (L1) is oper- ON
{Min. 28}
ated.
Arm throttle The arm throttle valve of
5 Min. 2.74
(R2) Boom RAISE and arm IN or OUT control valve (R2) is oper- ON
{Min. 28}
ated.
Boom throttle The boom throttle valve of
6 Boom RAISE and swing are oper- Min. 2.74
(R1) control valve (R1) is oper- ON
ated at the same time {Min. 28}
ated.
The travel pump and work
When the travel lever is operated
equipment/swing pump are OFF 0 {0}
independently
merged.
7 Straight-travel
When the travel lever and the work The travel pump and work
Min. 2.74
equipment/swing lever are oper- equipment/swing pump are ON
{Min. 28}
ated at the same time separated.
The boom LOWER safety
When the machine push-up switch
valve is set to high pres- OFF 0 {0}
Machine push- is turned on
8 sure.
up
When the machine push-up switch The boom LOWER safety Min. 2.74
ON
is turned off valve is set to low pressure. {Min. 28}
When the swing lock switch is
The swing brake operates. OFF 0 {0}
turned on or all levers are at neutral
Swing holding
9 When the swing lock switch is
brake The swing holding brake is Min. 2.74
turned off and the swing operation ON
released. {Min. 28}
starts
The basic pressure circuit to
When the lock lever is locked OFF 0 {0}
PPC oil pres- the PPC valve is blocked.
10
sure lock The basic pressure circuit to Min. 2.74
When the lock lever is released ON
the PPC valve is opened. {Min. 28}
The bucket PPC circuit of
All levers at neutral control valve (R2) is OFF 0 {0}
Bucket Hi can- opened.
11
cel The bucket PPC circuit of
Min. 2.74
Arm IN and bucket CURL control valve (R2) is ON
{Min. 28}
blocked.
PC2000-8 31
Adjusting work equipment and

swing PPC valve 1
a When the work equipment and swing lever tip

plays much, adjust according to the following
procedures.
k Lower the work equipment completely to
the ground, stop the engine and operate
the work equipment control lever several
times to relieve pressure remaining in the
pipe. Then, loosen the hydraulic tank oil
filler cap slowly and bring the safety lock
lever to the lock position.
a Lever play : 0.5 to 3 mm at the position of
200 mm from the center of the lever
mounting pin.
1. Remove bellows (1).
2. Loosen the locknut (2), turn the disc (3) to

adjust the lever play.
a At the time, do not move the piston.
3. Fix the disc (3) and tighten the locknut (2) by

applying the specified torque.
3 Locknut : 69 – 78 Nm {7 – 9 kgm}
32 PC2000-8
Testing and adjusting travel

deviation 1
Measurement
a Measure travel deviations under the following
conditions:
q Measuring position : Horizontal hard flat
ground
1. Start the engine and bring the work equipment

to the travel posture.
2. Set the working mode to the P Mode.
3. Run the machine 10 m with the engine at full

throttle and run it further 20 m as it is, then
measure the deviation (A).
PC2000-8 33
Adjusting
a Carry out troubleshooting for “H-16 Machine
deviates by itself during travel” to find out the
causal part in advance.
a Adjust the deviation with the motor idle run-
ning.
a If the main pump is adjusted for measures,
adjust the servo piston.
a Increase and decrease the maximum delivery
amount of the pump.
1. Fix adjustment screw (1) and loosen locknut

(2).
2. Adjust the maximum delivery amount by turn-

ing adjustment screw (1).
a If the adjustment screw:
q is turned clockwise, the delivery is
d ec r e as ed ( T h e tr a v el s p ee d i s
decreased)
q is turned counterclockwise, the deliv-
ery is increased (The travel speed is
increased)
a Amount adjusted by 45° angle turn of the
adjustment screw: 4.9 cm3/rev (equivalent
to the pump delivery amount)
a Criterion delivery amount of the pump
when shipped (For reference):
375 ± 2 cm3/rev
3. Fix adjustment screw (1) and tighten locknut

(2).
3 Locknut: 539 – 647 Nm {55 – 66 kgm}
34 PC2000-8
Testing work equipment hydraulic 2. Testing arm cylinder

drift cause portion 1 1) Stop the arm cylinder about 100 mm
before the IN stroke end and stop the
engine.
a When a hydraulic drift occurred to the work
equipment, follow the procedures below to
check if the cause has come from the cylinder
piston ring side or from the control valve side.
1. Testing boom cylinder and bucket cylinder

1) Take the same posture as that for measur-
ing hydraulic drift and stop the engine.
a Place the rated load or sand in the
bucket.
2) Operate the arm control lever to the “IN

side”.
q If the drift speed becomes faster, the
cylinder piston ring is defective.
q If the speed does not change, the
control valve is defective.
a Operate the control lever when the
starting switch is ON.
a When the accumulator pressure is 0,
run the engine for about 10 seconds
2) In case of boom, bring the boom control to accumulate pressure.
lever to the “RAISE side”, or in case of
bucket, bring the bucket control lever to [Reference] The reason why the above operation
the “CURL side”. makes the drift speed faster when the
q If the drift speed becomes faster, the cause of hydraulic drift is the cylinder
cylinder piston ring is defective. piston ring:
q If the speed does not change, the 1) In case of the above work equipment posture
control valve is defective. (the holding pressure rises on the bottom side),
a Operate the control lever when the oil leaks from the bottom side to the head side
starting switch is ON. but the head side volume is smaller than the
a When the accumulator pressure is 0, bottom side one by the rod. So, oil flowing in
run the engine for about 10 seconds from the bottom side increases the internal
to accumulate pressure. pressure on the head side.
2) As the internal pressure on the head side
increases, both pressures come to balance at a
certain pressure (depending on leakage), and
the drift speed becomes slow.
3) If the head side circuit opens to the drain circuit
at the time (the bottom side is closed with the
check valve) by the above lever operation, oil
will flow from the head side to the drain circuit.
Pressure will come not to balance, and the drift
speed will become faster.
PC2000-8 35
Testing oil leakage 1 2. Measurement of leakage from arm cylinder

1) Extend the cylinder fully and stop the
engine.
a Measure oil leakage under the following condi-
tions:
q Hydraulic oil temperature : within operating
temperature range
1. Measurement of leakage from boom cylin-

der
1) Extend the cylinder fully and stop the
engine.
2) Disconnect the pipes (2) from the head

side and block the pipe on the control
valve side with flange.
k Be careful not to disconnect the
pipe on the bottom side.
2) Disconnect the pipes (1) from the head

side and block the pipe on the control
valve side with flange.
k Be careful not to disconnect the
pipe on the bottom side.
3) Start the engine, operate the right control

lever to the “Arm IN” side at high idling
and apply the relief oil pressure to the cyl-
inder bottom side.
k Be careful not to operate the con-
trol lever to the “Arm OUT” side.
4) After 30 seconds elapsed, measure oil
leakage for 1 minute.
3) Start the engine, operate the left control

lever to the “Boom RAISE” side at high
idle and apply the relief oil pressure to the
cylinder bottom side.
trol lever to the “Boom LOWER”
side.
36 PC2000-8
3. Measurement of leakage from bucket cylin- 4. Measurement of leakage from swing motor
der k After the engine stopped, loosen the oil
1) Extend the cylinder fully and stop the filler cap of the hydraulic tank slowly to
engine. relieve pressure from the tank.
1) Disconnect the drain hose (4) from the
swing motor and block the hose side with
plug.
2) Disconnect the pipe (3) from the head side

and block the pipe on the control valve
side with flange.
k Be careful not to disconnect the 2) Start the engine and turn the swing lock
pipe on the bottom side. switch to the lock position.
3) Run the engine at high idle speed and
relieve the swing motor.
a Measure oil leakages several times while
moving the swing motor little by little (by
sliding the valve plate and the cylinder
block).
3) Start the engine, operate the left control

lever to the “Bucket CURL” side at high
idling and apply the relief oil pressure to
the cylinder bottom side.
trol lever to the “Bucket DUMP”
side.
PC2000-8 37
5. Measurement of leakage from travel motor 6. Measurement of leakage from center swivel
1) Start the engine and place a pin or a block joint
between the sprocket and the track frame 1) Start the engine and place a pin or a block
or the track link to lock the travel. between the sprocket and the track frame
k Make sure that the travel is locked or the track link to lock the travel.
certainly. k Make sure that the travel is locked
k After the engine stopped, loosen certainly.
the oil filler cap of the hydraulic k After the engine stopped, loosen
tank slowly to relieve pressure the oil filler cap of the hydraulic
from the tank. tank slowly to relieve pressure
2) Disconnect the drain hose (5) from the from the tank.
travel motor and block the hose side with 2) Disconnect the upper and lower measur-
plug. ing port hoses of the inspection port with
the upper and lower swivels and block the
hose side with plug or flange.
Inspection Measuring
Circuit
port port
A Right travel FORWARD T, A
B Right travel REVERSE A, C
C Left travel FORWARD P, D
D Left travel REVERSE D, T
3) Start the engine and operate the travel on

the measuring side at high idle to relieve
the travel motor.
a Measure oil leakages several times
while moving the travel motor little by
little (by sliding the valve plate and
the cylinder block).
3) Start the engine and operate the travel of

the measuring port at high idle to relieve
the travel motor.
k Check the inspection port and con-
duct the travel operation carefully.
a Measure oil leakages from the two
measuring ports of the lower swivel.
38 PC2000-8
Remaining pressure relief from

hydraulic circuit 1
k When disconnecting the pipe between the

control valve and the cylinder or the motor,
relieve pressure remaining in the circuit
according to the following procedures.
a No pressure remains in the travel motor circuit,
but the internal pressure of the hydraulic tank
influences the relief. So, open the cap of the
hydraulic tank.
1. Stop the engine and loosen the oil filler cap of

the hydraulic tank slowly to relieve pressure in
the tank.
2. Free the lock lever and operate the control

lever several times.
a When the control lever is operated 2 or 3
times, the pressure accumulated in the
accumulator is relieved completely.
3. Start the engine, idle it at low speed for about

10 seconds to accumulate pressure in the
accumulator, then stop the engine.
4. Repeat Steps 2 and 3 several times.
PC2000-8 39
Air bleeding from each component 1
1. Air bleeding from hydraulic pump
a After removing and installing the hydraulic 5) Loosen plug (5) for suction tube and
pump or changing hydraulic oil, bleed air check that oil flows out. Then, tighten the
from the hydraulic pump according to the plug temporarily.
following procedures.
k If air was not bled or air was bled insuf-
ficiently, the pump may be broken. So,
be sure to bleed air strictly according
to the procedures.
1) Loosen bleeders (1) – (3) of all hydraulic

pump 1 or 2 turns at the same time.
a Connect a tube [1] to each bleeder to
prevent oil from being scattered and
to receive oil in oil pan.
2) Feed hydraulic oil up to the specified level.
a Even after feeding oil to the hydraulic
tank, keep the oil filler cap removed.
3) After oil flew out from bleeder (3) of the
fan pump PF, tighten bleeder (3) tempo-
rarily.
4) After bleeders (1) and (2) of the main
pumps P1 and P2 stop bleeding air,
tighten only bleeder (2) of the main pump
P2 temporarily.
a Keep bleeder (1) of the main pump
P1 loose.
40 PC2000-8
6) Crank the engine and make sure that oil 2. Air bleeding from work equipment cylinder
flows out from bleeder (1) of the main circuit
pump P1. Then, tighten the bleeder tem-
porarily.
a For cranking, idle the engine at low
speed for 15 seconds twice.
7) Loosen the bleeder (2) of the main pump
P2.
8) Crank the rear engine and make sure that
oil flows out of the bleeder (2) of the main
pump P2. Then, tighten the bleeder tem-
porarily.
a For cranking, idle the engine at low
speed for 15 seconds twice.
9) Start the engine and keep it idle at low
speed.
10) Loosen the bleeders (1) – (3) of all
hydraulic pumps and make sure that bub- a When removing and installing the work
ble-free oil flows out of them. Then, equipment cylinder or when disconnecting
tighten these bleeders temporarily. and connecting the cylinder circuit piping,
11) Close the oil filler caps of the hydraulic bleed air from the work equipment cylinder
tank. according to the following procedures.
12) Keep the engine idling at low speed, raise k If air was not bled or air was bled insuf-
the work equipment from the ground and ficiently, the cylinder piston ring may
swing the upper structure 180°. be broken. So, be sure to bleed air
a After the swing, lower the work equip- strictly according to the procedures.
ment completely to the ground. 1) Start the engine and idle it at low speed for
13) Loosen plug (5) for the suction tube and about 5 minutes.
make sure that bubble-free oil flows out of 2) Repeat raising and lowering the boom 4 or
it. Then, tighten the plug. 5 times at the low idle.
3 Plug : 58.8 – 78.4Nm {6 – 8kgm} a Stop the piston rod about 100mm
14) Loosen the bleeders (1) – (3) of all before the stroke end and be careful
hydraulic pumps and make sure that bub- not to relieve it.
ble-free oil flows out of them. Then, 3) Execute Step 2) at high idle.
tighten these bleeders temporarily. 4) Bring the piston rod to the stroke end at
a This work is the same as in the above low idle and relieve it.
Step 10. 5) Execute Steps 2) – 4) for the arm and the
15) Keep the engine idling at low speed, raise bucket.
the work equipment from the ground and a When the cylinder was replaced, execute
swing the upper structure 180°. the procedures before connecting the
a Swing the upper structure in the work equipment. Especially, when the
reverse direction from the one in the boom cylinder was installed to the work
above Step 12. After the swing, lower equipment, the lowering side does not
the work equipment completely to the move to the stroke end.
ground.
16) Loosen the bleeders (1) – (3) of all
hydraulic pumps and make sure that bub-
ble-free oil flows out of them. Then,
tighten these bleeders.
3 Bleeder :
8.8 – 9.8Nm {0.9 – 1.0kgm}
17) Stop the engine.
18) Loosen the oil filler cap of the hydraulic
tank slowly and remove it. Relieve pres-
sure from the hydraulic tank and feed
hydraulic oil up to the specified level.
PC2000-8 41
3. Air bleeding from swing motor circuit 4. Air bleeding from swing motor circuit
(Swing motor) (Parking brake circuit)
a When removing and installing the swing a When removing and installing the swing
motor or when disconnecting and con- motor or when disconnecting and con-
necting the swing motor main circuit pipes, necting the swing holding brake circuit pip-
bleed air from the swing motor according ing, bleed air from the brake circuit
to the following procedures. according to the following procedures.
k If air was not bled or air was bled insuf- k If air was not bled or air was bled insuf-
ficiently, the swing motor may be dam- ficiently, the swing holding brake may
aged. So, be sure to bleed air strictly be dragged. So, be sure to bleed air
according to the procedures. strictly according to the procedures.
1) Start the engine and operate it while the 1) Start the engine and loosen bleeder (11).
engine is idling at low speed. a The bleeder is mounted on the front
2) Repeat operations of swing, start, and and rear swing motors.
stop 5 or 6 times. 2) Turn off the swing lock switch.
3) Swing the motor while the engine is idling
at low speed and make sure that bubble-
free oil flows out of bleeder (11). Then,
tighten the bleeders.
3 Bleeder :
8.8 – 9.8Nm {0.9 – 1.0kgm}
a The swing operation may be as faintly
as the swing oil pressure switch turns
on.
42 PC2000-8
5. Air Bleeding from travel motor circuit 6. Bleeding air from pilot selector valve circuit
(Travel motor)
a If the pilot selector valve circuit was dis-
connected and connected, bleed air from
it according to the following procedure.
k If the air bleeding operation is not per-
formed or all air is not bled, the work
equipment speed may decrease during
compound operation. Therefore, be
sure to bleed air according to the spec-
ified procedure.
1) Start the engine and loosen bleeders (1)

and (2).
a Pilot selector valves PV1 and PV2
have 1 bleeder each.
q Pilot selector valve PV1
a When removing and installing the travel
motor or when disconnecting and con-
necting the travel motor main circuit pipes,
bleed air from the travel motor according
to the following procedures.
k If air was not bled or air was bled insuf-
ficiently, the travel motor may be dam-
aged. So, be sure to bleed air strictly
according to the procedures.
1) Start the engine and loosen bleeder (12).
a The bleeder is mounted on the LH
and RH travel motors.
2) Make sure that bubble-free oil flows out of
the bleeders (12). Then, tighten the
bleeder. q Pilot service valve PV2
3 Bleeder :
8.8 – 9.8Nm {0.9 – 1.0kgm}
PC2000-8 43
2) While running the engine at low idle, move

the arm in and curl or dump the bucket
simultaneously. When oil containing no
bubbles flows out of bleeder (1), tighten
bleeder (1).
3 Bleeder:
8.8 – 9.8 Nm {0.9 – 1.0 kgm}
k Operate each lever slightly to a
d e gr ee th a t eac h o il pr ess ur e
3) Turn swing lock switch ON.
4) While running the engine at low idle, raise
the boom and swing the upper structure
simultaneously. When oil containing no
bubbles flows out of bleeder (2), tighten
bleeder (2).
3 Bleeder:
8.8 – 9.8 Nm {0.9 – 1.0 kgm}
k Operate each lever slightly to a
d e gr ee th a t eac h o il pr ess ur e
44 PC2000-8
Air bleeding from PPC circuit 1

a When removing and installing the control valve
or when disconnecting and connecting PPC
hose, bleed air from the PPC circuit according
to the following procedures.
If air was not bled or air was bled insufficiently,
time lag or abnormal sound may occur. So, be
sure to bleed air strictly according to the proce-
dures.
1. Start the engine and loosen the bleeder (13).

a The bleeders are installed on the wiring
harness spring case elbow of the control
valve spool (28 places in total).
2. Control each actuator while the engine is idle

at low speed.
3. Make sure that bubble-free oil flows out of

bleeder (13). Then, tighten bleeder.
3 Bleeder: 8.8 – 9.8 Nm {0.9 – 1.0 kgm}
k The operation of each lever should be

enough to the extent that each hydrau-
lic switch turns on.
4. The circuits and places to be bled are as fol-

lows.
A : Arm IN circuit (3 places),
Q : Boom RAISE circuit (3 places),
T : Bucket CURL circuit (4 places),
U : Travel REVERSE circuit (4 places),
a : Arm OUT circuit (4 places),
q : Boom LOWER circuit (2 places),
t : Bucket DUMP circuit (4 places),
u : Travel FORWARD circuit (4 places)
PC2000-8 45
q Front side of control valve
q Rear side of control valve
46 PC2000-8
Testing and adjusting auto grease system 1
1. Indication of abnormality by auto grease

controller
If the auto grease system has abnormality, the
auto grease caution lamp lights up red and the
auto grease caution mark is indicated in the
machine monitor.
Indication by machine
Lamp Abnormality Cause
monitor
• Pump trouble
Lighting Refer to figure Pump is running but pressure in • No grease
up 9JH10486 grease piping does not rise. • Breakage of grease piping
or leakage
2. Adjusting delivery from injector 3) Tighten locknut (3) and install the cap of
a The delivery from the injector is adjusted the adjustment screw.
when shipped. If necessary, increase or
decrease the delivery according to the fol-
lowing procedure.
1) Remove the cap from the adjustment
screw and loosen locknut (3).
2) Turn adjustment screw (2) to adjust the
delivery.
a If the adjustment screw
q is turned clockwise, the delivery
is reduced.
q is turned counterclockwise, the
delivery is increased.
a Delivery increase or decrease by 1
turn of adjustment screw: 0.17 cc/st
a Limit dimension (a) of the adjustment
screw to 10 mm.
a If the adjustment screw is tightened
fully to reduce dimension (a) to 10 mm,
the delivery is 0.13 cc/st.
PC2000-8 47
3. Bleeding air from grease pump line 5. Bleeding air from injector line
a When a new machine is delivered or a When a new machine is delivered or
transported disassembled or when the transported disassembled or when the
grease can becomes empty or when the grease can becomes empty or when the
hose, pump, or injector is replaced, bleed hose, pump, or injector is replaced, bleed
air from the grease pump line according to air from the grease pump line according to
the following procedure. the following procedure.
1) Set the grease mode selector switch to a Perform this work after “Bleeding air from
the MANUAL position. distributor line” is finished.
2) Operate the grease gun to bleed air from a Perform this work on the all distributor
the grease pump line. lines.
a Check that the grease discharged 1) Set the grease mode selector switch to
from the grease gun does not contain the MANUAL position.
air. 2) Remove plug (5) of the injector.
3) Using the grease gun, supply grease
4. Bleeding air from distributor line through service nipple (6) to the injector
a When a new machine is delivered or line.
transported disassembled or when the
grease can becomes empty or when the
hose, pump, or injector is replaced, bleed
air from the grease pump line according to
the following procedure.
a Perform this work after “Bleeding air from
grease pump line” is finished.
a Perform this work on the all distributor
lines in order from the one nearest to the
grease pump (Swing circle → Boom cylin-
der bottom → Boom → Arm).
1) Set the grease mode selector switch to
the MANUAL position.
2) Remove plug (4) of the distributor.
4) Install plug (5).

3 Plug:
3.92 – 5.88 Nm {0.4 – 0.6 kgm}
3) Check that the grease discharged from

the plug hole does not contain air.
3 Plug:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
48 PC2000-8
6. Check of completion of air bleeding

Check that the indicator (7) of each injector is
operating normally with the auto grease sys-
tem operating.
a If the indicator reciprocates vertically, it is
normal.
a If the indicator does not operate normally,

air has not been bled completely. In this
case, perform procedures 3 – 5 again.
7. Method of supplying grease manually

a If the auto grease system has a trouble
and cannot supply grease automatically.
In this case, supply grease manually
1) Set the grease mode selector switch to
the MANUAL position.
2) Remove plug (5) of the injector.
3) Using the grease gun, supply grease
through service nipple (6) to the injector
line.

3 Plug:
3.92 – 5.88 Nm {0.4 – 0.6 kgm}
PC2000-8 49
Adjusting mirrors 1 2. Adjusting mirrors (a1) and (a2)

Adjust these mirrors so that the operator can
see from left side to left rear of the machine.
q The mirrors are installed to the following 4 a Angle from machine side (a) : 70°
positions.
a: Cab at left front of machine
b: Floor around cab at left front of machine
c: Handrail at left rear of machine
d: Handrail at right center of machine
3. Adjusting mirror (b)

Adjust this mirror so that the operator can see
the catwalk.
a Angle from machine side (b) : 60°
1. Loosen nut (1), bolt (2) and screw (3) of each
mirror and adjust the mirrors to decided dimen-
sion and angle as following items.
a Adjust the mirrors (c: Handrail at left rear
of machine, and d: Handrail at right center
of machine) so that the operator can par-
ticularly see persons at the right and left
rear ends of the machine.
a Adjust the mirrors so that the operator can
see persons (or things 1 m high and about
30 cm in diameter) at the right and left rear
ends of the machine.
50 PC2000-8
4. Adjusting mirrors (c1) and (c2) 5. Adjusting mirrors (d1) and (d2)
q c1: Adjust so that the operator can see q d1: Adjust so that the operator can see
the left rear end of the machine. the right lower end of the fuel tank.
q c2: Adjust so that the operator can see q d2: Adjust so that the operator can see
the left rear end of the counterweight. the right rear lower end of the
machine.
q L dimension : 86 mm
q M dimension : 200 mm q P dimension : 303 mm
q N dimension : 270 mm q Q dimension : 35 mm
q Angle (c) : 30° q R dimension : 604 mm
q Angle (d) : 30°
q Angle (e) : 45°
PC2000-8 51
SEN02008-00
© 2006 KOMATSU
All Rights Reserved
52
SEN02009-00
PC2000-8

PC2000-8 20001 and up

Special functions of machine monitor................................................................................................... 2
Handling controller voltage circuit ...................................................................................................... 57
PC2000-8 1

Special functions of machine monitor 1
For all specifications
2 PC2000-8
Upper section of machine monitor (Display sec-

tion)
(a): Multi-display
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambi-
ent temperature and the condition of the bat-
tery. In this case, the machine monitor goes off
for a moment. This phenomenon is not a fail-
ure, however.
Upper section of machine monitor (Switch sec-

tion)
[F1]: F1 function switch
a The function of each function switch is indi-
cated by graphic mark in the multi-display (a)
above that function switch.
a If the graphic mark of a function switch is not
displayed, that function switch is not working.
Lower section of machine monitor (Switch sec-

tion)
[1]: Numeral 1 input switch/Auto-decelerator
switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Heavy lift shifting
switch
[4]: Numeral 4 input switch/Alarm buzzer cancel
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Windshield washer
switch
[7]: Numeral 7 input switch
Switch having no numerals: No function
a Each switch has the function indicated by
graphic mark and the function of inputting a
numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of multi-
display.
PC2000-8 3
t Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary function and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
Page Page
t Operator mode (Outline) Service mode
6p 18p
A Display of KOMATSU logo 6p Monitoring 19p
A Display of check before starting 6p Abnormality Mechanical Systems 27p
A Display of warning after check before starting 7p Record Electrical Systems 28p
A Display of ending of maintenance interval 7p Maintenance Record 35p
A Display of check of working mode 7p Maintenance Mode Change 36p
A Display of ordinary screen 7p Phone Number Entry 38p
B Change of ordinary screen 7p Key-on Mode 39p
A Display of end screen 8p Unit 40p
B Selection of auto-deceleration and auto low idle 8p Default Maintenance Password 41p
B Selection of working mode 8p Camera 42p
B Selection of heavy lift 9p ECO Display 43p
O (Special operation)
B Operation to stop alarm buzzer 9p Pump Absorption Torque 44p

B Operation of windshield wiper 10p Adjustment of auto grease pump dis-
45p
charge pressure
B Operation of window washer 10p
Interval adjustment of auto grease 45p
B Display of auto grease monitor 10p
Operating time adjustment of auto
B Display of truck counter 11p 45p
grease pump
Operation to display camera mode
B
(if camera is installed)
11p Adjustment Setting of grease start time after oper- 45p
ation
B Operation to display clock and service meter 12p Selection of fan speed mode 46p
B Check of maintenance information 12p Adjustment of RAD fan 100% speed 46p
B Setting and display of user mode 12p Adjustment of O/C fan 100% speed 46p
C Display of energy-saving guidance 13p Adjustment of RAD fan 70% speed 47p
C Display of caution monitor 13p Adjustment of O/C fan 70% speed 47p
C Display of user code and failure code 13p Cylinder Cut-Out 48p
O (Special operation) No Injection 51p
Function of checking display of LCD Fuel Consumption 52p
D 15p
(Liquid Crystal Display)
Snap shot 54p
D Function of checking service meter 15p
PM clinic 55p
D Function of changing maintenance password 16p
4 PC2000-8
a Classification of operator mode

A: Display/Function from time when starting switch is turned ON to time when screen changes to ordi-
nary screen and display after starting switch is turned OFF
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch
PC2000-8 5
t Operator mode (Outline) a Display pattern of operator mode

a Only outline of the operator mode is described The contents of display from the time when
in this section. For details of contents/opera- starting switch is turned ON to time when
tion of each function/display, see the “Struc- screen changes to ordinary screen depends on
ture, function and maintenance standard”, or the setting and condition of the machine.
“Operation and Maintenance Manual”. Other than D and B
a The following are the displays or functions of D : When there is abnormal item in check-
the operator mode explained in this section before-starting items
(including some items which need special E : When there is maintenance item which is
operations). not maintained after specified interval
Display Display of KOMATSU logo

pattern
When the s tarting switch is turned ON, the
B D E
KOMATSU logo is displayed for 2 seconds.
Display of KOMATSU logo 1 1 1 a After the KOMATSU logo is displayed for 2
Display of check before starting 2 2 2 seconds, the screen changes to “Display of
Display of warning after check before starting — 3 — check before starting”.
Display of ending of maintenance interval — — 3
Display of check of working mode 3 — —
Display of ordinary screen 4 4 4
Change of ordinary screen
Display of end screen
Selection of auto-deceleration and auto low idle
Selection of working mode
Selection of heavy lift
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of wind washer
Display of auto grease monitor
Display of truck counter Display of check before starting
Operation to display camera mode When the screen changes to the check-before-
(if camera is installed) starting screen, the check before starting is carried
Operation to display clock and service meter out for 2 seconds.
Check of maintenance information a If any abnormality is detected by the check
Setting and display of user mode before starting, the screen changes to “Display
of warning after check before starting” or “Dis-
Display of energy-saving guidance
play of ending of maintenance interval”.
Display of caution monitor
a If no abnormality is detected by the check
Display of user code and failure code before starting, the screen changes to “Display
O (Special operation) of check of working mode and travel speed”.
Function of checking display of LCD a The monitors (6 pieces) displayed on the screen
(Liquid Crystal Display) are the items under the check before starting.
Function of checking service meter
Function of changing maintenance password
6 PC2000-8
Display of warning after check before starting Display of check of working mode
If any abnormality is detected by the check before If the check before starting is finished normally, the
starting, the warning monitor is displayed on the screen to check the working mode is displayed for
screen. 2 seconds.
a The following figure shows that the engine oil a After display of check of the working mode is
level monitor (a) is warning of low of engine oil finished, the screen changes to “Display of
level. ordinary screen”.
Display of ending of maintenance interval Display of ordinary screen

When the check before starting is carried out, if a If the machine monitor starts normally, the ordinary
maintenance item is near or after the end of the set screen is displayed.
interval, the maintenance monitor is displayed for a Service meter (a) or a clock is displayed at the
30 seconds to urge the operator to maintenance. center upper section of the screen (The ser-
a This screen is displayed only when the mainte- vice meter or clock is selected with [F4]).
nance function is effective. The color of the a ECO gauge (b) is displayed at the right end of
maintenance monitor (yellow or red) indicates the screen (It is turned ON and OFF in the ser-
the length of the time after the maintenance vice mode).
interval.
a Set or change the maintenance function in the
service mode.
a After display of this screen is finished, the
screen changes to “Display of check of work-
ing mode and travel speed”.
Change of ordinary screen

In the ordinary screen, 2 screens of 1/2 and 2/2 can
be selected. When the machine monitor is started,
1/2 screen is displayed.
a Press F1 once to change the 1/2 or 2/2
screens alternately.
PC2000-8 7
Display of end screen a If the auto low idle setting is turned “ON” from
When the starting switch is turned OFF, the end the user menu, the auto low idle function is
screen is displayed for 5 seconds. shifted between effective and ineffective in the
a Another message may be displayed on the order of “ON” — “OFF” — “ON” each time the
end screen, depending on the message dis- auto-deceleration switch is pressed.
play function of KOMTRAX.
Selection of working mode

Selection of auto-deceleration and auto low idle Select a working mode according to the following
While the ordinary screen is displayed, if the auto- procedure.
deceleration switch is pressed, large auto-deceler- 1. While the ordinary screen is displayed, press
ation monitor (a) is displayed for 2 seconds and the the working mode selector switch, and the
setting of the auto-deceleration is changed. working mode selection screen is displayed.
a Each time the auto-deceleration switch is
pressed, the auto-deceleration is turned ON
and OFF alternately.
a If the auto-deceleration is turned ON, large
monitor (a) and auto-deceleration monitor (b)
are displayed simultaneously.
a If the auto-deceleration is turned OFF, auto-
deceleration monitor (b) goes off.
2. Operate the function switches or working mode

selector switch to select and confirm the work-
ing mode which you will use.
Function switches
q [F3]: Move to lower working mode
q [F4]: Move to upper working mode
q [F5]: Cancel selection and return to ordi-
nary screen
q [F6]: Confirm selection and return to ordi-
nary screen
Working mode selector switch
q Press: Move to lower working mode
q Hold down:Confirm selection and return to
ordinary screen
8 PC2000-8
a If you do not touch any of the function Selection of heavy lift

switches and working mode selector If the heavy lift switch is pressed with the ordinary
switch for 5 seconds, the selection is con- screen displayed, large monitor (a) of heavy lift is
firmed and the screen changes to the ordi- displayed for 2 seconds and the heavy lift setting is
nary screen. changed.
a Each time the heavy lift switch is pressed, the
heavy lift is turned ON and OFF alternately.
a If the heavy lift is turned ON, large monitor (a)
and heavy lift monitor (b) are displayed simul-
taneously.
a If the heavy lift is turned OFF, heavy lift monitor
(b) goes off.
3. When the ordinary screen is displayed again,

large working mode monitor (a) is displayed for
2 seconds, and then the setting of the working
mode is changed.
a When large monitor (a) is displayed, the
display of working mode monitor (b) is
changed, too.
Operation to stop alarm buzzer

While the alarm buzzer is sounding, if the alarm
buzzer cancel switch is pressed, the alarm buzzer
stops.
a Even if the alarm buzzer cancel switch is
pressed, the screen does not change.
PC2000-8 9
Operation of windshield wiper If the grease level lowers below the specified level
While the ordinary screen is displayed, if the wiper while the normal screen is displayed, grease level
switch is pressed, large wiper monitor (a) is dis- caution lamp (b) lights.
played for 2 seconds and the windshield wiper
starts or stops.
a Each time the wiper switch is pressed, the
windshield wiper setting is changed to INT, ON
(continuos, upper/lower), ON (continuos,
upper), OFF, and INT again in order.
a When large monitor (a) is displayed, the dis-
play of wiper monitor (b) is changed or turned
OFF, too.
a If the windshield wiper is turned OFF, large
monitor (a) is not displayed.
If the manual grease switch on the console is

pressed while the normal screen is displayed, man-
ual grease monitor (c) is displayed at the center of
the monitor and grease is supplied.
When greasing is completed, manual grease moni-
tor (c) goes off.
Operation of window washer

While the ordinary screen is displayed, if the win-
dow washer switch is pressed, the washing liquid is
splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen does not change.
Display of auto grease monitor

If grease is supplied by the auto grease function If the auto grease system has abnormality, large
while the normal screen is displayed, auto grease auto grease caution mark (d) is displayed at the
monitor (a) lights. center of the monitor for 2 seconds and then small
When greasing is completed, auto grease monitor caution mark (e) is displayed.
(a) goes off.
10 PC2000-8
Display of truck counter

While the normal screen is displayed, the number
of times of pressing the truck counter switch on the
work equipment control lever can be displayed.
There are truck counter 1 switch and truck counter
2 switch on the work equipment control lever. Each
time truck counter 1 switch is pressed, the number
in “a” increases by 1. Each time truck counter 2
switch is pressed, the number in “b” increases by 1.
a If a caution is generated in the camera mode,

the caution monitor is displayed at the left
upper of the screen (The low hydraulic oil tem-
perature caution is not displayed there, how-
ever).
a When an error that there is a user code occurs
in the camera mode, if you do not touch any
control lever for 10 seconds, the screen
changes to the ordinary screen and displays
Operation to display camera mode (if camera is the error information.
a When two or more cameras are connected, the
installed)
image of one of them or the images of two of
When a camera is installed, if [F3] is pressed, the them can be displayed.
multi-display changes to the camera image (Set the a If 2-camera image display [F4] is selected, the
connection of the camera in the service mode). image of camera 1 is displayed on the left side
of the screen and the image of camera 2 is dis-
played on the right side. The image of camera
3 is displayed only singly.
a If the images of 2 cameras are displayed
simultaneously, images are displayed at inter-
vals of 1 second on the right and left screen.
PC2000-8 11
Operation to display clock and service meter Setting and display of user mode
While the ordinary screen is displayed, press [F4], While the ordinary screen is displayed, press [F6],
and section (a) changes to the service meter and and the user menu screen is displayed.
clock alternately.
a When the clock is selected, adjust the time, set
12-hour or 24-hour display, and set the sum-
mer time with the user mode function.
a There are following items in the user menu.

Screen Adjustment
ECO Display
Clock Adjustment
Check of maintenance information Language
Economy Mode Adjustment
While the maintenance monitor or ordinary screen
is displayed, press [F5], and the maintenance table Auto Low Idle
screen is displayed. Truck Counter Modification/Clear
Hydraulic Fan Reserve
a To reset the time left after finishing mainte-

nance, more operations are necessary.
12 PC2000-8
Display of energy-saving guidance Display of user code and failure code

When the machine is set in a certain operating con- If an abnormality which displays a user code and a
dition, the energy-saving guidance screen is dis- failure code occurs on the ordinary screen or cam-
played automatically to urge the operator to the era mode screen, all the information of the abnor-
energy-saving operation. mality is displayed.
a The energy-saving guidance is displayed when (a): User code (3 digits)
the following condition is satisfied while the (b): Failure code (5 or 6 digits)
display setting is set effective in the service (c): Telephone mark
mode. (d): Telephone No.
a Condition for display: a This screen is displayed only when an abnor-
Engine is running + All levers have been in mality (failure code) for which a user code is
neutral for 5 minutes + Caution (Note) or user set occurs.
code is not generated (Note) a The telephone mark and telephone No. are
Note: Excluding hydraulic oil low temperature displayed only when the telephone No. is reg-
caution istered in the service mode.
a If any lever or pedal is operated, or [F5] is a If multiple abnormalities occur simultaneously,
pressed, the screen returns to the ordinary all the codes are displayed repeatedly in order.
screen. a Since the information of the displayed failure
code is recorded in the abnormality record in
the service mode, check the details in the ser-
vice mode.
Display of caution monitor

If an abnormality which displays a caution monitor
occurs on the ordinary screen or camera mode
screen, the caution monitor is displayed large for a a When the caution monitor is also displayed,
moment and then displayed at (a) in the screen. the telephone mark is not displayed.
a On the camera mode screen, the caution mon-
itor flashes at the left upper of the screen when
the caution is generated.
PC2000-8 13
a Remedies given by displayed user codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
User code Failure mode Action
Move the swing brake cancel switch up to release the brake.
When applying the swing brake, operate the swing lock switch
E03 Swing brake system error manually. Depending on the cause of the problem, it may not
be possible to release it. In any case, have inspection carried
out immediately.
An error occurs in the electronic control system of the pump.
Emergency avoidance function is underway.
E07 Pump control system error Some functions of the machine are disabled.
Move machine to the safe place, and have inspection carried
out immediately.
Engine controller power source error
E10 Engine controller drive system circuit error Have inspection carried out immediately.
(engine stopped)
Engine controller system error
Operate machine to a safe posture and have inspection carried
E11 (Output reduced to protect engine)
out immediately.
Fan drive system error
Operate machine to a safe posture and have inspection carried
E14 Abnormality in throttle system
out immediately.
Engine sensor (coolant temperature, fuel Operations are possible, but have inspection carried out
E15
pressure, oil pressure) system error immediately.
Network error Operate machine to a safe posture and have inspection carried
E0E
Solenoid power supply system error out immediately.
14 PC2000-8
Function of checking display of LCD (Liquid Function of checking service meter

Crystal Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are as follows. At this time, only the service meter sec-
operated as follows, all the LCD (Liquid Crystal Dis- tion displays.
play) lights up in white. q Operation of switches (simultaneous): [4] + [1]
q Operation of switches (simultaneous): [4] + [F2] a Since there is some time lag in start of the
a When finishing the operation of the switches, LCD, hold down the switches until the LCD dis-
release [F2] first. plays normally.
a If there is a display error in the LCD, only that a After the machine monitor is used continu-
part is indicated in black. ously, blue points (points which do not go off)
a The LCD panel sometimes has black points may be seen on this screen. This phenomenon
(points which are not lighted) and bright points does not indicate a failure or a defect.
(points which do not go off) for the reason of its
characteristics. If the number of the bright
points and black points does not exceed 10,
those points are not a failure or a defect.
a To return to the former screen, press the func-
tion switch.
PC2000-8 15
Function of changing maintenance password 3. After the New password input screen is dis-
When changing the maintenance password used played, input a new password with the numeral
for the maintenance setting function, follow these input switches and confirm it with the function
procedures. switch.
1. While the ordinary screen is displayed, perform a Set a new password of 4 – 6 digits (If it
the following operation with the numeral input has only 3 or less digits or has 7 or more
switches. digits, it is not accepted).
q Operation of switches (While pressing [4], q [F5]: Reset input numeral/Return to ordi-
perform the operation in order): nary screen
[4] + [5] o [5] o [5] q [F6]: Confirm input numeral
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.
4. After the New password input screen is dis-

played again, input a new password again with
the numeral input switches and confirm it with
2. After the Maintenance PASSWORD screen is the function switch.
displayed, input the current password with the q [F5]: Reset input numeral/Return to ordi-
numeral input switches and confirm it with the nary screen
function switch. q [F6]: Confirm input numeral
q [F5]: Reset input numeral/Return to ordi- a If a password different from the password
nary screen input before is input, the message to input
q [F6]: Confirm input numeral again is displayed.
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to input the password again is dis-
played.
16 PC2000-8
5. If the screen to notify completion of setting is

displayed and then the ordinary screen is dis-
played, the password is changed successfully.
PC2000-8 17
t Service mode a The items which can be selected in the

To change the operator mode to the service mode, service menu are as follows (including
perform the following operation. some items which need special opera-
This operation is always required when you use the tions).
service mode. 01 Monitoring
1. Check of display of screen and operation of Abnormality Mechanical Systems

02
switches Record Electrical Systems
While the ordinary screen is displayed, perform 03 Maintenance Record
the following operation with the numeral input
switches. 04 Maintenance Mode Change
q Operation of switches (While pressing [4], 05 Phone Number Entry
perform the operation in order): Key-on Mode
[4] + [1] o [2] o [3]
a This operation of the switches is accepted Unit
only while the ordinary screen is displayed. 06 Default Maintenance Password
Camera
ECO Display
Pump Absorption Torque
Adjustment of auto grease pump
discharge pressure
Interval adjustment of auto grease
Operation time adjustment of auto
grease pump
Setting of grease start time after
operation
07 Adjustment
Selection of fan speed mode
Adjustment of RAD fan 100%
speed
2. Selection of service menu Adjustment of O/C fan 100%
When the Service menu screen is displayed, speed
the service mode is selected. Select a service Adjustment of RAD fan 70%
menu you use with the function switches or speed
numeral input switches.
Adjustment of O/C fan 70% speed
q [F3]: Move to lower menu
q [F4]: Move to upper menu 08 Snap shot
q [F5]: Return to ordinary screen (operator 09 Cylinder Cut-Out
mode)
10 No Injection
q [F6]: Confirm selection
a You may enter a 2-digit code with the 11 Fuel Consumption
numeral input switches to select the menu 12 PM clinic
of that code and confirm it with [F6].
18 PC2000-8
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc.
1. Selecting menu
Select “Monitoring” on the service menu
screen.
3. Deciding monitoring items

After selecting monitoring items, execute moni-
toring with the function switch or numeral input
switch.
a Execution with function switch: Double-
click or hold down [F6] (about 2 seconds).
a Execution with numeral input switch: Input
[99999] and press [F6].
a When monitoring only 2 items, for exam-
ple, select them and confirm with [F6]. If
[F6] is pressed once more at this time,
2. Selecting monitoring items monitoring is executed.
After the “Monitoring selection menu screen” is a If monitoring items are selected up to the
displayed, select items to be monitored with limit number, monitoring is executed auto-
t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t matically.
switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Reset input numeral/Return to ser-
vice menu screen
a Selection with function switches: Select an
item with [F3] or [F4] and confirm it with
[F6].
a Selection with numeral input switches:
Enter a 5-digit code, and the item of that
code is selected directly. Confirm that item
with [F6].
a If the color of the selected box changes
from yellow to red, selection of the item of
that box is confirmed.
a Up to 6 monitoring items can be selected
at a time. You may not able to set up to 6
items, however, depending on the display
form of those items.
PC2000-8 19
4. Executing monitoring 6. Changing machine setting mode

After the “Executing monitoring screen” is dis- To change the setting of the working mode,
played, perform the necessary operation of the travel speed, or auto-deceleration during moni-
machine and check the monitoring information. toring, operate the corresponding switch under
a Monitoring information is indicated by the current condition, and the mode setting
value, ON/OFF, or special display. screen is displayed.
a The unit of display can be set to “SI unit”, While this screen is displayed, if the corre-
“metric unit”, or “inch unit” with the Initial- sponding switch is operated further, the corre-
ization function in the service mode. sponding mode is changed.
a After finishing changing the setting, press
[F6] to return to the monitoring information
screen.
a If the setting is changed during monitoring,
the new setting is held even after the
screen returns to the ordinary screen after
monitoring is finished.
5. Holding monitoring information

The monitoring information can be held and
reset with the function switches.
q [F3]: Reset holding
q [F4]: Hold information (displayed data)
q [F5]: Return to monitoring selection menu
screen
20 PC2000-8
Monitoring items table

Code Component in Unit (Initial setting: ISO)
Monitoring item
No. charge ISO meter inch
00200 Controller Model Select PUMP (1st) —
00201 Machine ID ENG (1st) —
00203 Machine ID ENG (2nd) —
01601 2nd Engine Speed Command PUMP (1st) r/min rpm rpm
12100 1st Engine Speed Command PUMP (1st) r/min rpm rpm
01002 Engine speed ENG (1st), PUMP r/min rpm rpm
01006 Engine speed PUMP (2nd) r/min rpm rpm
10001 RAD Fan Speed PUMP (1st) r/min rpm rpm
10004 O/C Fan Target Speed PUMP (1st) r/min rpm rpm
04206 Fuel Level PUMP (1st) % % %
01124 P1F Pump Pressure PUMP (1st) MPa kg/cm2 psi
01125 P1R Pump Pressure PUMP (1st) MPa kg/cm2 psi
2
01126 P2F Pump Pressure PUMP (1st) MPa kg/cm psi
01127 P2R Pump Pressure PUMP (1st) MPa kg/cm2 psi
01132 RAD Fan Pump Pressure PUMP (1st) MPa kg/cm2 psi
01134 O/C Fan Pump Pressure PUMP (1st) MPa kg/cm2 psi
2
07400 Boom Raise PPC Pressure PUMP (2nd) MPa kg/cm psi
07500 Boom Lower PPC Pressure PUMP (2nd) MPa kg/cm2 psi
07200 Arm Curl PPC Pressure PUMP (2nd) MPa kg/cm2 psi
07600 Arm Dump PPC Pressure PUMP (2nd) MPa kg/cm2 psi
2
07300 Bucket Curl PPC Pressure PUMP (2nd) MPa kg/cm psi
07301 Bucket Dump PPC Pressure PUMP (2nd) MPa kg/cm2 psi
09001 Swing Left PPC Pressure PUMP (2nd) MPa kg/cm2 psi
09002 Swing Right PPC Pressure PUMP (2nd) MPa kg/cm2 psi
2
13804 VR1 J/S Diff Pressure PUMP (1st) MPa kg/cm psi
13805 VL1 J/S Diff Pressure PUMP (1st) MPa kg/cm2 psi
13806 VR2 J/S Diff Pressure PUMP (1st) MPa kg/cm2 psi
13807 VL2 J/S Diff Pressure PUMP (1st) MPa kg/cm2 psi
2
13900 Auto Grease Disc Pressure PUMP (2nd) MPa kg/cm psi
36400 L/B Rail Pressure ENG (1st) MPa kg/cm2 psi
36403 R/B Rail Pressure ENG (2nd) MPa kg/cm2 psi
36500 L/B Charge Pressure ENG (1st) kPa kg/cm2 psi
2
37200 Engine Oil Pressure ENG (1st) kPa kg/cm psi
37400 Ambient Pressure ENG (1st) kPa kg/cm2 psi
42800 Blowby Pressure VHMS kPa kg/cm2 psi
04401 Hydr. Oil Temperature PUMP (2nd) °C °C °F
04405 VHMS Hydr. Oil Temperature VHMS °C °C °F
37501 Ambient Temperature VHMS °C °C °F
04107 Coolant Temperature ENG (1st) °C °C °F
14200 L/B Fuel Temperature ENG (1st) °C °C °F
14203 R/B Fuel Temperature ENG (2nd) °C °C °F
18400 Intake Temperature ENG (1st) °C °C °F
18500 Charge Temperature ENG (1st) °C °C °F
42700 Engine Oil Temperature ENG (1st) °C °C °F
30000 PTO Oil Temperature VHMS °C °C °F
42600 L/B1-3 Exhaust Temperature VHMS °C °C °F
42601 L/B4-6 Exhaust Temperature VHMS °C °C °F
42608 R/B1-3 Exhaust Temperature VHMS °C °C °F
42609 R/B4-6 Exhaust Temperature VHMS °C °C °F
01307 P1F Pump EPC Act Current PUMP (1st) mA mA mA
PC2000-8 21

Monitoring item
01309 P1R Pump EPC Act Current PUMP (1st) mA mA mA
01311 P2F Pump EPC Act Current PUMP (1st) mA mA mA
01313 P2R Pump EPC Act Current PUMP (1st) mA mA mA
31624 RAD Fan Pump EPC Current PUMP (1st) mA mA mA
31634 O/C Fan Pump EPC Current PUMP (1st) mA mA mA
01128 P1F Pump Press Volt PUMP (1st) V V V
01129 P1R Pump Press Volt PUMP (1st) V V V
01130 P2F Pump Press Volt PUMP (1st) V V V
01131 P2R Pump Press Volt PUMP (1st) V V V
04403 Hydr. Oil Temp Sensor Volt PUMP (2nd) V V V
04406 VHMS Hydr. Oil Temp Sens Volt VHMS V V V
01133 RAD Fan Pump Press Sensor Volt PUMP (1st) V V V
01135 O/C Fan Pump Press Sensor Volt PUMP (1st) V V V
03200 Battery Volt PUMP V V V
04300 Battery Charge Volt MON V V V
07201 Arm Curl PPC Press Volt PUMP (2nd) V V V
07302 Bucket Curl PPC Press Volt PUMP (2nd) V V V
07303 Bucket Dump PPC Press Volt PUMP (2nd) V V V
07401 Boom Raise PPC Press Volt PUMP (2nd) V V V
07501 Boom Lower PPC Press Volt PUMP (2nd) V V V
07601 Arm Dump PPC Press Volt PUMP (2nd) V V V
09003 Swing Left PPC Press Volt PUMP (2nd) V V V
09004 Swing Right PPC Press Volt PUMP (2nd) V V V
13808 VR1 J/S Diff Press Volt PUMP (1st) V V V
13809 VL1 J/S Diff Press Volt PUMP (1st) V V V
13810 VR2 J/S Diff Press Volt PUMP (1st) V V V
13811 VL2 J/S Diff Press Volt PUMP (1st) V V V
13901 Auto Grease Disc Press Volt PUMP (2nd) V V V
37505 Ambient Air Temp Sens Volt VHMS V V V
03000 Fuel Dial Pos Sens Volt ENG (1st) V V V
03203 L/B Battery Power Supply ENG (1st) V V V
03206 R/B Battery Power Supply ENG (2nd) V V V
04105 Coolant Temp Sens Volt ENG (1st) V V V
04200 Fuel Level Sensor Volt MON V V V
14201 L/B Fuel Temp Sens Volt ENG (1st) V V V
14202 R/B Fuel Temp Sens Volt ENG (2nd) V V V
17201 L/B PCV Close Timing ENG (1st) CA CA CA
17202 R/B PCV Close Timing ENG (2nd) CA CA CA
18401 Intake Temp Sens Volt ENG (1st) V V V
18501 Charge Temp Sens Volt ENG (1st) V V V
36401 L/B Rail Pressure Sens Volt ENG (1st) V V V
36404 R/B Rail Pressure Sens Volt ENG (2nd) V V V
36501 Charge Press Sens Volt ENG (1st) V V V
37201 Eng Oil Press Sens Volt ENG (1st) V V V
37401 Ambient Press Sens Volt ENG (1st) V V V
42701 Eng Oil Temp Sens Volt ENG (1st) V V V
30001 PTO Oil Temp Sens Volt VHMS V V V
42603 L/B1-3 Exhaust Temp Sens Volt VHMS V V V
42604 L/B4-6 Exhaust Temp Sens Volt VHMS V V V
42605 R/B1-3 Exhaust Temp Sens Volt VHMS V V V
42607 R/B4-6 Exhaust Temp Sens Volt VHMS V V V
22 PC2000-8

Monitoring item
42802 Blowby Pressure Sens Volt VHMS V V V
01307 P1F Pump EPC Current PUMP (1st) mA mA mA
01309 P1R Pump EPC Current PUMP (1st) mA mA mA
01311 P2F Pump EPC Current PUMP (1st) mA mA mA
01313 P2R Pump EPC Current PUMP (1st) mA mA mA
10002 RAD Fan Target Speed (70%) PUMP (1st) r/min rpm rpm
10003 RAD Fan Target Speed (Max) PUMP (1st) r/min rpm rpm
10005 O/C Fan Target Speed (70%) PUMP (1st) r/min rpm rpm
10006 O/C Fan Target Speed (Max) PUMP (1st) r/min rpm rpm
31623 RAD Fan Pump EPC Current PUMP (1st) mA mA mA
31633 O/C Fan Pump EPC Current PUMP (1st) mA mA mA
17500 Engine Power Mode ENG (1st) — — —
18600 Inject Fueling Command ENG (1st) mg/st mg/st mg/st
18700 Engine Output Torque ENG (1st) Nm kgm lbft
31701 Throttle Position ENG (1st) % % %
31706 Final Throttle Position ENG (1st) % % %
36200 Rail Press Command ENG (1st) MPa kg/cm2 psi
36300 Injection Timing Command ENG (1st) CA CA CA
36700 Engine Torque Ratio ENG (1st) % % %
13113 Pump Total Torque PUMP (1st) Nm kgm lbft
13114 RAD Fan Pump Torque PUMP (1st) Nm kgm lbft
13115 O/C Fan Pump Torque PUMP (1st) Nm kgm lbft
13116 P1F Pump Target Torque PUMP (1st) Nm kgm lbft
13117 P1F Pump Actual Torque PUMP (1st) Nm kgm lbft
13118 P1R Pump Target Torque PUMP (1st) Nm kgm lbft
13119 P1R Pump Actual Torque PUMP (1st) Nm kgm lbft
13120 P2F Pump Target Torque PUMP (1st) Nm kgm lbft
13121 P2F Pump Actual Torque PUMP (1st) Nm kgm lbft
13122 P2R Pump Target Torque PUMP (1st) Nm kgm lbft
13123 P2R Pump Actual Torque ENG (1st) Nm kgm lbft
37300 Fuel Rate ENG (1st) l/h l/h gal/h
Pressure Switch 1 PUMP (2nd)
Boom Lower PUMP (2nd)
01900 Boom Raise PUMP (2nd) ON or OFF
Arm Curl PUMP (2nd)
Arm Dump PUMP (2nd)
Bucket Curl PUMP (2nd)
01901 ON or OFF
Bucket Dump PUMP (2nd)
Service PUMP (2nd)
Swing Left PUMP (2nd)
01902 Swing Right PUMP (2nd) ON or OFF
Travel Left PUMP (2nd)
Travel Right PUMP (2nd)
Solenoid Valve 1 PUMP (2nd)
Travel Straight PUMP (2nd)
02300 ON or OFF
Swing Brake PUMP (2nd)
2-Stage Relief PUMP (2nd)
PC2000-8 23

Monitoring item
Swing Priority PUMP (2nd)
02301 ON or OFF
Bucket Hi Cancel PUMP (2nd)
Boom Throttle PUMP (2nd)
Back Press Competing/L PUMP (2nd)
02302 ON or OFF
Arm Throttle/L PUMP (2nd)
Arm Throttle/R PUMP (2nd)
Solenoid Valve 4 PUMP (1st)
RAD Fan Reverse PUMP (1st)
02303 ON or OFF
O/C Fan Reverse PUMP (1st)
Auto Grease PUMP (1st)
Switch Input 1 PUMP (2nd)
02200 Swing Release Sw PUMP (2nd) ON or OFF
Swing Brake Sw PUMP (2nd)
Pump 2 Model Select 1 PUMP (2nd)
02205 ON or OFF
Switch Input 3 PUMP (1st)
02206 Key Switch (ACC) PUMP (1st) ON or OFF
Key Switch (C) PUMP (1st)
Manual Grease PUMP (1st)
Fuel Level Hi PUMP (1st)
02307 ON or OFF
Fuel Level Mid PUMP (1st)
Fuel Level Low PUMP (1st)
Grease Lo Level PUMP (1st)
Key Switch (ACC) PUMP (2nd)
Key Switch (C) PUMP (2nd)
02308 ON or OFF
Wiper Upper Sw PUMP (2nd)
Wiper Upper Limit Sw PUMP (2nd)
Wiper Lower Limit Sw PUMP (2nd)
Pump 1 Model Select 1 PUMP (1st)
02209 ON or OFF
Step Light Switch PUMP (2nd)
02210 ON or OFF
Horn Switch PUMP (2nd)
Ladder Down Signal PUMP (2nd)
24 PC2000-8

Monitoring item
Controller Output 1 PUMP (2nd)
Wiper Upper On PUMP (2nd)
03700 Wiper Upper Brake PUMP (2nd) ON or OFF
Wiper Lower On PUMP (2nd)
Wiper Lower Brake PUMP (2nd)
Controller Output 2 PUMP (2nd)
Step L. Relay PUMP (2nd)
03701 Flash L. Relay PUMP (2nd) ON or OFF
Travel Alarm PUMP (2nd)
Washer Relay PUMP (2nd)
Controller Output 3 PUMP (1st)
03702 Auto Grease Caution PUMP (1st) ON or OFF
Fan Reverse PUMP (1st)
Controller Output 4 PUMP (1st)
03703 ON or OFF
Battery Relay Output PUMP (1st)
Monitor input 1 MON
Key Switch MON
Start MON
04500 ON or OFF
Preheat MON
Light MON
Rad. Level MON
Monitor Input 2 MON
Aircleaner MON
04501 ON or OFF
Engine Oil Level MON
Battery Charge MON
Monitor Input 3 MON
04502 ON or OFF
Swing Brake Sw MON
VHMS Input 1 VHMS
Hyd Oil Level Sw VHMS
Hyd Oil Level Filter Clog Sw VHMS
40966 ON or OFF
Truck Counter Sw1 VHMS
Truck Counter Sw2 VHMS
PTO Oil Lv Sw/Opt VHMS
Orbcomm Communication Status VHMS
Controller Power VHMS
99003 ON or OFF
Satellite Condition VHMS
Data Transmission VHMS
20216 ECM Build Version ENG (1st) —
20217 L/B ECM Calibration Data Ver ENG (1st) —
20218 R/B ECM Calibration Data Ver ENG (2nd) —
18900 L/B ECM Internal Temp ENG (1st) °C °C °F
18902 R/B ECM Internal Temp ENG (2nd) °C °C °F
20400 L/B ECM S/N ENG (1st) —
20401 R/B ECM S/N ENG (2nd) —
20227 Monitor Ass'y P/N MON —
20402 Monitor Serial No MON —
20228 Monitor Prog. P/N MON —
20229 Pump Con1 Ass'y P/N PUMP (1st) —
20403 Pump Con1 Serial No PUMP (1st) —
20230 Pump Con1 Prog. P/N PUMP (1st) —
PC2000-8 25

Monitoring item
20249 Pump Con2 Ass'y P/N PUMP (2nd) —
20407 Pump Con2 Serial No PUMP (2nd) —
20220 Pump Con2 Prog. P/N PUMP (2nd) —
a Entry order of items in table

The items are entered in the order of display on the monitoring selection menu screen.
a Unit
The display unit can be set to “ISO”, “meter”, or “inch” freely (Set it with “Unit selecting” in Initialization of
the service menu).
“CA” in the display unit is an abbreviation for crankshaft angle.
“mg/st” in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of monitoring information.
ENG: The engine controller is in charge of detection of monitoring information.
PUMP: The pump controller is in charge of detection of monitoring information.
VHMS: The VHMS controller is in charge of detection of monitoring information.
26 PC2000-8
Abnormality Record (Mechanical Systems)

The machine monitor classifies and records the
abnormalities which occurred in the past or which
are occurring at present into the mechanical sys-
tems, electrical systems, and air-conditioning sys-
tem or heater system.
To check the mechanical system abnormality
record, perform the following procedures.
1. Selecting menu
Select “Abnormality Record” on the “Service
Menu” screen.
3. Information displayed on “abnormality record”

screen
On the “Mechanical Systems” screen, the fol-
lowing information is displayed.
(a) : Occurrence order of abnormalities from
latest one/Total number of records
(b) : Failure code
(c) : Contents of trouble
(d) : Number of occurrence time (Displayable
range: 0 – 65,535 times)
(e) : Service meter reading at first occurrence
(f) : Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
2. Selecting sub menu played)
After the “Abnormality Record” screen is dis- q [F2]: Move to previous page (screen) (if
played, select “Mechanical Systems” with the displayed)
function switches or numeral input switches. q [F5]: Return to abnormality record screen
q [F3]: Move to lower item a If no abnormality record is recorded, “No
q [F4]: Move to upper item abnormality record” is displayed.
q [F5]: Return to service menu screen a If the number of occurrence time is 1 (first
q [F6]: Confirm selection occurrence), the service meter reading at
a You may enter a 2-digit code with the the first occurrence and that at the last
numeral input switches to select the record occurrence are the same.
of that code and confirm it with [F6]. a If [E] is displayed on the left of a failure
a The following figure shows the display of code, the abnormality is still occurring or
the air conditioner specification. The resetting of it has not been confirmed.
heater specification and heaterless speci- a For all the failure codes that the machine
fication are different from each other in the monitor can record, see the failure codes
display of “03 Air-conditioning System”, table in “Abnormality Record (Electrical
which may not be displayed in the heater- Systems)”.
less specification.
PC2000-8 27
4. Resetting abnormality record

The contents of the mechanical system
abnormality record cannot be reset.
Abnormality Record (Electrical Systems)

The machine monitor classifies and records the
abnormalities which occurred in the past or which
are occurring at present into the mechanical sys-
tems and electrical systems.
To check the electrical system abnormality record,
perform the following procedures.
1. Selecting menu
Select “Abnormality Record” on the “Service 3. Information displayed on “abnormality record”
Menu” Screen. screen
On the “Electrical Systems” screen, the follow-
ing information is displayed.
(a) : Occurrence order of abnormalities from
latest one/Total number of records
(b) : Failure code
(c) : Contents of trouble
(d) : Number of occurrence time (Displayable
range: 0 – 65,535 times)
(e) : Service meter reading at first occurrence
(f) : Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if
displayed)
2. Selecting sub menu q [F4]: Move to upper item
After the “Abnormality Record” screen is dis- q [F5]: Return to “abnormality record” screen
played, select “Electrical Systems” with the a If no abnormality record is recorded, “No
function switches or numeral input switches. abnormality record” is displayed.
q [F3]: Move to lower item a If the number of occurrence time is 1 (first
q [F4]: Move to upper item occurrence), the service meter reading at
q [F5]: Return to service menu screen the first occurrence and that at the last
q [F6]: Confirm selection occurrence are the same.
a You may enter a 2-digit code with the a If [E] is displayed on the left of a failure
numeral input switches to select the code, the abnormality is still occurring or
record of that code and confirm it with resetting of it has not been confirmed.
[F6]. a For all the failure codes that the machine
a The following figure shows the display of monitor can record, see the failure codes
the air conditioner specification. The table.
heater specification and heaterless speci-
fication are different from each other in the
display of “03 Air-conditioning System”,
which may not be displayed in the heater-
less specification.
28 PC2000-8
4. Resetting abnormality record 3) After the “Electrical Sys. Error Reset”

1) While the “Electrical Systems” screen is screen is displayed, operate the function
displayed, perform the following operation switches.
with the numeral input switches. q [F5]: Return to “Electrical systems”
q Operation of switches (While pressing screen (Reset mode)
[4], perform the operation in order): q [F6]: Execute reset
[4] + [1] o [2] o [3] a The following figure shows the screen
displayed when the items are reset
one by one (which is a little different
from the screen displayed when all
the items are reset together).
2) Check that the screen is set in the reset

mode, and then reset the items one by
one or together with the function switches.
a If the screen is set in the reset mode,
[CLEAR] graphic mark is indicated at 4) If the screen to notify completion of reset
[F2]. is displayed and then the “Electrical Sys-
q [F2]: Reset all items tems” (reset mode) screen is displayed,
q [F3]: Move to lower item the reset of the abnormality record is com-
q [F4]: Move to upper item pleted.
q [F5]: Return to abnormality record a After a while, the screen returns to
screen the “Electrical Systems” screen.
q [F6]: Reset selected item
a To reset items one by one: Select the
item to be reset with [F3] or [F4] and
press [F6].
a To reset all items together: Press [F2],
and all the items are reset, regardless
of selection of the items.
a If [E] is displayed on the left of a fail-
ure code, the resetting operation is
accepted but the information is not
reset.
PC2000-8 29
Failure code table
User Applicable History

Failure code Failure contents
code equipment classification
0410KA Fuel LV. Sensor Failure — MON Electrical system
0410KB Fuel LV. Sensor Failure — MON Electrical system
8800ZG Auto grease abnormally — PUMP Mechanical system
7@HAZL VR1/P1F Relief Press Abnormality — PUMP Mechanical system
7@HBZL VL1/P1R Relief Press Abnormality — PUMP Mechanical system
7@HCZL VR2/P2F Relief Press Abnormality — PUMP Mechanical system
7@HDZL VL2/P2R Relief Press Abnormality — PUMP Mechanical system
AA10NX Aircleaner Clogging — MON Mechanical system
AB00KE Change Voltage Low — MON Mechanical system
B@BAZG Eng. Oil Press. Low — ENG Mechanical system
B@BAZK Eng. Oil Level Low — MON Mechanical system
B@BCNS Eng. Water Overheat — ENG Mechanical system
B@BCZK Eng. Water Lvl Low — MON Mechanical system
B@CBNS VHMS
High PTO Temperature — VHMS
[n5o61] [n5o61]
B@HANS Hydr. Oil Overheat — PUMP Mechanical system
CA111 ECM Critical Internal Failure E10 ENG Electrical system
CB111 ECM Critical Internal Failure E10 ENG Electrical system
CA115 Eng. Ne and Bkup Speed Sens Error E10 ENG Electrical system
CB115 Eng. Ne and Bkup Speed Sens Error E10 ENG Electrical system
CA122 Chg Air Press Sensor High Error E11 ENG Electrical system
CA123 Chg Air Press Sensor Low Error E11 ENG Electrical system
CA131 Throttle Sensor High Error E14 ENG Electrical system
CA132 Throttle Sensor Low Error E14 ENG Electrical system
CA135 Eng Oil Press Sensor High Error E15 ENG Electrical system
CA141 Eng Oil Press Sensor Low Error E15 ENG Electrical system
CA144 Coolant Temp Sens High Error E15 ENG Electrical system
CA145 Coolant Temp Sens Low Error E15 ENG Electrical system
CA153 Chg Air Temp Sensor High Error E15 ENG Electrical system
CA154 Chg Air Temp Sensor Low Error E15 ENG Electrical system
CA187 Sens Supply 2 Volt Low Error E15 ENG Electrical system
CB187 Sens Supply 2 Volt Low Error E15 ENG Electrical system
CA212 Eng Oil Temp Sensor High Error E15 ENG Electrical system
CA213 Eng Oil Temp Sensor Low Error E15 ENG Electrical system
CA221 Ambient Press Sens High Error E15 ENG Electrical system
CA222 Ambient Press Sens Low Error E15 ENG Electrical system
CA227 Sens Supply 2 Volt High Error E15 ENG Electrical system
CB227 Sens Supply 2 Volt High Error E15 ENG Electrical system
CA234 Eng Over Speed E15 ENG Electrical system
CA238 Ne Speed Sens Supply Volt Error E15 ENG Electrical system
CB238 Ne Speed Sens Supply Volt Error E15 ENG Electrical system
CA263 Fuel Temp Sensor High Error E15 ENG Electrical system
CB263 Fuel Temp Sensor High Error E15 ENG Electrical system
30 PC2000-8

CA265 Fuel Temp Sensor Low Error E15 ENG Electrical system
CB265 Fuel Temp Sensor Low Error E15 ENG Electrical system
CA271 IMV/PCV1 Short Error E10 ENG Electrical system
CB271 IMV/PCV1 Short Error E10 ENG Electrical system
CA272 IMV/PCV1 Open Error E10 ENG Electrical system
CB272 IMV/PCV1 Open Error E10 ENG Electrical system
CA273 PCV2 Short Error E10 ENG Electrical system
CB273 PCV2 Short Error E10 ENG Electrical system
CA274 PCV2 Open Error E10 ENG Electrical system
CB274 PCV2 Open Error E10 ENG Electrical system
CA322 Inj #1(L#1) Open/Short Error E11 ENG Electrical system
CA342 Calibration Code Incompatibility E10 ENG Electrical system
CB342 Calibration Code Incompatibility E10 ENG Electrical system
CA351 Injectors Drive Circuit Error E10 ENG Electrical system
CB351 Injectors Drive Circuit Error E10 ENG Electrical system
CA441 Battery Voltage Low Error E10 ENG Electrical system
CB441 Battery Voltage Low Error E10 ENG Electrical system
CA442 Battery Voltage High Error E10 ENG Electrical system
CB442 Battery Voltage High Error E10 ENG Electrical system
CA449 Rail Press Very High Error E11 ENG Electrical system
CB449 Rail Press Very High Error E11 ENG Electrical system
CA451 Rail Press Sensor High Error E11 ENG Electrical system
CB451 Rail Press Sensor High Error E11 ENG Electrical system
CA452 Rail Press Sensor Low Error E11 ENG Electrical system
CB452 Rail Press Sensor Low Error E11 ENG Electrical system
CA553 Rail Press High Error E15 ENG Electrical system
CB553 Rail Press High Error E15 ENG Electrical system
CA554 Rail Press Sensor In Range Error E11 ENG Electrical system
CB554 Rail Press Sensor In Range Error E11 ENG Electrical system
CA559 Rail Press Low Error E15 ENG Electrical system
CB559 Rail Press Low Error E15 ENG Electrical system
CA689 Eng Ne Speed Sensor Error E15 ENG Electrical system
CB689 Eng Ne Speed Sensor Error E15 ENG Electrical system
CA691 Intake Air Temp Sens High Error E15 ENG Electrical system
CA692 Intake Air Temp Sens Low Error E15 ENG Electrical system
PC2000-8 31

CA731 Eng Bkup Speed Sens Phase Error E15 ENG Electrical system
CB731 Eng Bkup Speed Sens Phase Error E15 ENG Electrical system
CA757 All Persistent Data Lost Error E10 ENG Electrical system
CB757 All Persistent Data Lost Error E10 ENG Electrical system
CA778 Eng Bkup Speed Sensor Error E15 ENG Electrical system
CB778 Eng Bkup Speed Sensor Error E15 ENG Electrical system
CA781 CEN Communication Error E0E ENG Electrical system
CB781 CEN Communication Error E0E ENG Electrical system
CA1117 Persistent Data Lost Error E10 ENG Electrical system
CB1117 Persistent Data Lost Error E10 ENG Electrical system
CA1257 Harness Key Error E0E ENG Electrical system
CB1257 Harness Key Error E0E ENG Electrical system
CB1548 Inj #7(R#1) Open/Short Error E11 ENG Electrical system
CA1633 KOMNET Data link Time out Error E0E ENG Electrical system
CA2185 Throt Sens Sup Volt High Error E14 ENG Electrical system
CA2186 Throt Sens Sup Volt Low Error E14 ENG Electrical system
CA2249 Rail Press Very Low Error E11 ENG Electrical system
CB2249 Rail Press Very Low Error E11 ENG Electrical system
CA2555 Grid Heater Relay Volt Low Error E15 ENG Electrical system
CA2556 Grid Heater Relay Volt High Error E15 ENG Electrical system
D110KB Battery Relay Drive S/C — PUMP Electrical system
D163KB Flash Light Relay S/C — PUMP Electrical system
D195KA Step Light Relay Disc — PUMP Electrical system
D195KY Step Light Relay S/C — PUMP Electrical system
D1E9KB Wiper Drive Relay 1 S/C — PUMP Electrical system
D1EAKB Wiper Drive Relay 2 S/C — PUMP Electrical system
D1EBKB Low Wiper Brake Relay Short Circuit — PUMP Electrical system
D1ECKB Upper Wiper Brake Relay Short Circuit — PUMP Electrical system
DA22KK Pump 1 Solenoid Power Low Error E0E PUMP Electrical system
dA22KK Pump 2 Solenoid Power Low Error E0E PUMP Electrical system
DA25KP Pump 1 Sens Supply Vol Low Error E07 PUMP Electrical system
dA25KP Pump 2 Sens Supply Vol Low Error — PUMP Electrical system
DA26KP 5V Sensor 2 Power Abnormality E07 PUMP Electrical system
DA29KQ Pump 1 Model Select Abnormality — PUMP Electrical system
dA29KQ Pump 2 Model Select Abnormality — PUMP Electrical system
DA2RMC CAN Discon (Pump 1 Con Detected) E0E PUMP Electrical system
dA2RMC CAN Discon (Pump 2 Con Detected) E0E PUMP Electrical system
DA2TMC Pump Comm. ECM Child Abnormality — PUMP Electrical system
DH25KX VR1/P1F J/S Dif Press Sensor Abnormality E07 PUMP Electrical system
32 PC2000-8

DH26KX VL1/P1R J/S Dif Press Sensor Abnormality E07 PUMP Electrical system
DHPEKX VR1/P1F Pump P. Sensor Abnormality E07 PUMP Electrical system
DHPFKX VL1/P1R Pump P. Sensor Abnormality E07 PUMP Electrical system
DHPGKX VR2/P2F Pump P. Sensor Abnormality E07 PUMP Electrical system
DHPHKX VL2/P2R Pump P. Sensor Abnormality E07 PUMP Electrical system
DHPSKX Auto Grease Press Sensor Abnormality — PUMP Electrical system
DHPTKX Fan(RAD) Pump P. Sensor Open Circuit — PUMP Electrical system
DHPUKX Fan(O/C) Pump P. Sensor Open Circuit — PUMP Electrical system
DHS3KX Arm Dig PPC Press Sensor Abnormality — PUMP Electrical system
DHS4KX Bucket Curl PPC Press Sensor Abnormality — PUMP Electrical system
DHS8KX Boom Raise PPC Press Sensor Abnormality — PUMP Electrical system
DHS9KX Boom Lower PPC Press Sensor Abnormality — PUMP Electrical system
DHSAKX Swing Right PPC Press Sensor Abnormality — PUMP Electrical system
DHSBKX Swing Left PPC Press Sensor Abnormality — PUMP Electrical system
DHSCKX Arm Dump PPC Press Sensor Abnormality — PUMP Electrical system
DHSDKX Bucket Dump PPC Press Sensor Abnormality — PUMP Electrical system
DUM3KB Auto Grease Caution LED Short Circuit — PUMP Electrical system
DUM4KB FAN Reverse LED Short Circuit — PUMP Electrical system
DV20KB Travel Alarm S/C — PUMP Electrical system
DW41KA Swing Priority Sol Open Circuit — PUMP Electrical system
DW41KB Swing Priority Sol Short Circuit — PUMP Electrical system
DW45KA Swing Brake Sol. Disc. E03 PUMP Electrical system
DW45KB Swing Brake Sol. S/C E03 PUMP Electrical system
DW91KA Straight-Travel Sol. Disc. PUMP Electrical system
DW91KB Straight-Travel Sol. S/C — PUMP Electrical system
DW4XKA Bucket Curl Hi Cancel Sol. Disc. — PUMP Electrical system
DW4XKB Bucket Curl Hi Cancel Sol. S/C — PUMP Electrical system
DW7BKA Fan Motor(RAD) Reverse Sol Open Circuit — PUMP Electrical system
DW7BKB Fan Reverse Sol S/C — PUMP Electrical system
DW7HKA Fan Motor(O/C) Reverse Sol Open Circuit — PUMP Electrical system
DW7HKB Fan Motor(O/C) Reverse Sol Short Circuit — PUMP Electrical system
DWA3KA Arm throttle Valve/L Sol Open Circuit — PUMP Electrical system
DWA3KB Arm throttle Valve/L Sol Short Circuit — PUMP Electrical system
DWA4KA Arm throttle Valve/R Sol Open Circuit — PUMP Electrical system
DWA4KB Arm throttle Valve/R Sol Short Circuit — PUMP Electrical system
DWA5KA Auto Grease Sol Open Circuit — PUMP Electrical system
DWA5KB Auto Grease Sol Short Circuit — PUMP Electrical system
DWA6KA Boom throttle Valve Sol Open Circuit — PUMP Electrical system
DWA6KB Boom throttle Valve Sol Short Circuit — PUMP Electrical system
DWK0KA 2-stage Relief Sol. Disc. — PUMP Electrical system
DWK0KB 2-stage Relief Sol. S/C — PUMP Electrical system
DWK2KA Back Press Comp Valve Sol Open Circuit — PUMP Electrical system
PC2000-8 33

DWK2KB Back Press Comp Valve Sol Short Circuit — PUMP Electrical system
DWN5KA Fan(RAD) Pump Epc Sol Open Circuit E11 PUMP Electrical system
DWN5KB Fan(RAD) Pump Epc Sol Short Circuit E11 PUMP Electrical system
DWNCKA Fan(O/C) Pump Epc Sol Open Circuit E11 PUMP Electrical system
DWNCKB Fan(O/C) Pump Epc Sol Short Circuit E11 PUMP Electrical system
DXAAKA P1F EPC Sol Disc E07 PUMP Electrical system
DXAAKB P1F EPC Sol S/C E07 PUMP Electrical system
DXABKA P1R EPC Sol Disc E07 PUMP Electrical system
DXABKB P1R EPC Sol S/C E07 PUMP Electrical system
DXACKA P2F EPC Sol Disc E07 PUMP Electrical system
DXACKB P2F EPC Sol S/C E07 PUMP Electrical system
DXADKA P2R EPC Sol Disc E07 PUMP Electrical system
DXADKB P2R EPC Sol S/C E07 PUMP Electrical system
DY2CKB Washer Drive S/C — PUMP Electrical system
DY20MA Low Wiper Working Abnormality — PUMP Electrical system
DY2FMA Upper Wiper Working Abnormality — PUMP Electrical system
LA10ZL RAD Fan Pump Relief Press Abnormality — PUMP Mechanical system
LA20ZL O/C Fan Pump Relief Press Abnormality — PUMP Mechanical system
34 PC2000-8
Maintenance Record a The following items can be selected in the

The machine monitor records the maintenance maintenance record.
information of the filters, oils, etc., which the opera- 01 Engine oil change
tor can display and check by the following opera- 02 Engine oil filter change
tions. When maintenance is carried out, if the data
03 Fuel main filter change
are reset in the operator mode, the number of the
41 Fuel pre-filter change
times of maintenance is recorded in this section.
04 Hydraulic oil filter change
05 Hydraulic tank breather change
1. Selecting menu 06 Corrosion resistor change
Select “Maintenance Record” on the “Service 07 PTO case oil change
Menu” screen. 08 Final drive case oil change
09 Machinery case oil change
10 Hydraulic oil change
30 Hydraulic oil pilot filter change
31 Hydraulic oil drain filter change
42 Oil cooler accumulator change
3. Items displayed on maintenance record screen

The following items are displayed.
(a) : Maintenance items
(b) : Number of times of replacement up to now
(c) : Service meter reading (SMR) at previous
replacement
2. Selecting maintenance record item

After the “Maintenance Record” screen is dis-
played, select an item to be checked with the
function switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F5]: Return to service menu screen
a You may enter a 2-digit code with the
numeral input switches to select the item
of that code.
PC2000-8 35
Maintenance Mode Change a The following items can be selected on

The operating condition for maintenance function in the Change of maintenance mode screen.
the operation mode can be set and changed with 01 Engine oil change
this menu. 02 Engine oil filter change
q Set function effective or ineffective
03 Fuel main filter change
q Change set replacement interval (by items)
41 Fuel pre-filter change
q Initialize all set replacement intervals
04 Hydraulic oil filter change
1. Selecting menu 05 Hydraulic tank breather change
Select of “Maintenance Mode Change” on the 06 Corrosion resistor change
“Service Menu” screen. 07 PTO case oil change
08 Final drive case oil change
09 Machinery case oil change
10 Hydraulic oil change
30 Hydraulic oil pilot filter change
31 Hydraulic oil drain filter change
42 Oil cooler accumulator change
3. Contents of setting of Maintenance mode on/

off
After selecting “Maintenance Mode On/Off”, if
the screen is displayed, set ON or OFF with
the function switches.
q ON: Functions of all maintenance items
are set effective in operator mode
2. Selecting sub menu q OFF: Functions of all maintenance items
After the “Maintenance Mode Change” screen are set ineffective in operator mode
is displayed, select an item to change the set- q [F3]: Move to lower item
ting with the function switches or numeral input q [F4]: Move to upper item
switches. q [F5]: Cancel selection and return to Main-
q [F1]: Move to next page (screen) tenance mode change screen
q [F2]: Move to previous page (screen) q [F6]: Confirm selection and return to
q [F3]: Move to lower item Maintenance mode change screen
q [F4]: Move to upper item a Even if ON/OFF of each item has been
q [F5]: Return to service menu screen set, if the above setting is changed, it is
a You may enter a 2-digit code with the applied.
numeral input switches to select the item
of that code and confirm it with [F6].
36 PC2000-8
4. Contents of setting of each maintenance item 5. Function of initializing all items

After selecting each maintenance item, if the After selecting “All Default Value”, if the screen
screen is displayed, set the item with the func- is displayed, set with the function switches.
tion switches. q If this operation is executed, the set val-
q Initial value: Maintenance interval set in ues of all the maintenance items are ini-
machine monitor (Recommended by man- tialized.
ufacturer and not changeable). q [F5]: Return to Maintenance mode change
q Set value: Maintenance interval which can screen
be set freely. Maintenance functions in q [F6]: Execute initialization
operator mode operate on basis of this set a A while after [F6] is pressed, the initializa-
time (which is increased or decreased by tion completion screen is displayed. Then,
50 hours). if the “Maintenance Mode Change” screen
q ON: Maintenance function of this item is is displayed, initialization is completed.
set effective in operator mode.
q OFF: Maintenance function of this item is
set ineffective in operator mode.
q [F3]: Select Reduce set value (Upper) or
OFF (Lower).
q [F4]: Select Increase set value (Upper) or
ON (Lower).
q [F5]: Cancel setting before confirmation
and return to Maintenance mode
change screen.
q [F6]: Confirm setting of upper or lower line.
a After the setting of the upper and lower
lines is confirmed with [F6] and the screen
changes to the Maintenance mode
change screen with [F5], the setting is
effective.
a If the set value of an item set to “ON” is
changed after 1 or more operating hours
since the start of setting, the change is
recognized as a resetting operation.
PC2000-8 37
Phone Number Entry a If [F6] is pressed without inputting a digit,

The telephone No. displayed when the user code/ there is not information of telephone No.
failure code is displayed in the operator mode can Accordingly, no telephone No. is displayed
be input and changed according to the following in the operator mode.
procedure.
If a telephone No. is not input with this function, no
telephone No. is displayed in the operator mode.
1. Selecting menu
Select “Phone Number Entry” on the “Service
Menu” screen.
2. Registering and changing telephone No.

After the “Phone Number Entry” screen is dis-
played, register or change the telephone No.
q [F2]: Reset all input No.
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Reset input digit/Return to service
menu
q [F6]: Confirm input
a Up to 14 digits can be input from the left.

Input nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (orange background) and over-
write it with the correct digit.
38 PC2000-8
Default (Key-on Mode) 3. Selecting mode

Check or change various settings related to the After the “Key-on Mode” screen is displayed,
machine monitor and machine by “Default”. select the mode to be set with the function
The function of working mode with key ON is used switches.
to set the working mode displayed on the machine q Power Mode: [P] is displayed when key is
monitor when the starting switch is turned ON. ON
q Economy Mode: [E] is displayed when key
1. Selecting menu is ON
Select “Default” on the “Service Menu” screen. q Mode at Previous Key-off: Final mode in
previous operation is displayed when key
is ON
q [F5]: Cancel selection and return to
“Default” screen
q [F6]: Confirm selection and return to
a When the machine is delivered, Mode at
previous key-OFF is set.
2. Selecting sub menu

After the “Default” screen is displayed, select
“Key-on Mode” with the function switches or
a Select this item similarly to an item on the
“Service Menu” screen.
PC2000-8 39
Default (Unit) 3. Selecting unit

Check or change various settings related to the After the “Unit” screen is displayed, select the
machine monitor and machine by “Default”. unit to be set with the function switches.
The unit selecting function is used to select the unit q [F3]: Move to lower unit
of the data displayed for monitoring, etc. q [F4]: Move to upper unit
q [F5]: Cancel selection and return to
1. Selecting menu “Default” screen
Select “Default” on the “Service Menu” screen. q [F6]: Confirm selection and return to
a When the machine is delivered, the SI unit
system is set.

“Unit” with the function switches or numeral
input switches.
40 PC2000-8
Default (Maintenance Password) 3. Selecting Disable/Enable

Check or change various settings related to the After the Maintenance Password screen is dis-
machine monitor and machine by “Default”. played, select the setting with the function
The function of setting maintenance password is switches.
used to set the display of the password screen q Disable : Password screen is not dis-
when the functions related to the maintenance are played
used in the operator mode. q Enable : Password screen is displayed
q [F3] : Move to lower item
1. Selecting menu q [F4] : Move to upper item
Select “Default” on the “Service Menu” screen. q [F5] : Cancel selection and return to
q [F6] : Confirm selection and return to

“Maintenance Password” with the function
switches or numeral input switches. 4. Displaying maintenance password screen
a Select this item similarly to an item on the When the following operation is performed, the
“Service Menu” screen. password screen is displayed in the operator
mode.
q Maintenance mode: The Maintenance
table screen is changed to the Mainte-
nance interval reset screen.
5. Changing maintenance password

The password can be changed by operating
the switches specially in the operator mode.
a See Maintenance password changing
function in the operator mode.
a Default password: [000000]
a If the password setting is changed from
“Enable” to “Disable”, the password is
reset to the default. When “Enable” is set
again, be sure to set a new password.
a The maintenance password is different
from the engine start lock password.
PC2000-8 41
Default (Camera) 3. Selecting camera setting

Check or change various settings related to the After the “Camera” setting screen is displayed,
machine monitor and machine by “Default”. select the setting with the function switches.
The camera setting function is used to set installa- q OFF: Camera is not used
tion and removal of a camera. q Original Image: Image of connected cam-
era is displayed in origi-
1. Selecting menu nal position (as in mirror,
Select “Default” on the “Service Menu” screen. used as back monitor)
q Reverse Image: Image of connected cam-
era is displayed in reverse
position (as seen directly,
used as front or side mon-
itor)
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel setting before confirmation
and return to “Default” screen
q [F6]: Confirm selection in each line
a After “Camera” screen is displayed, cam-
era 1 can be always set. When 2 or more
cameras are connected, if camera 1 is set,
the screen changes to setting of camera 2
automatically.
2. Selecting sub menu a After confirming the setting of each line
After the “Default” screen is displayed, select with [F6], return to the “Default” screen
“Came ra ” wi th t he func tio n swi tch es or with [F5], and the setting is effective.
numeral input switches. a If a camera is connected but not set nor-
a Select this item similarly to an item on the mally with this function, the graphic mark
“Service Menu” Screen. of camera is not displayed at [F3] in the
operator mode. Accordingly, the image of
the camera cannot be used.
a If 2 or more cameras are connected, be
sure to set the use of them from camera 1
in order.
a The function of displaying 2 images simul-
taneously is effective when use of camera
1 and camera 2 is set.
a When a camera is installed, check that the
displayed image is not inverted horizon-
tally.
42 PC2000-8
Default (ECO Display) a If ECO display is turned ON, ECO is dis-

Check or change various settings related to the played when the screen changes to the
machine monitor and machine by “Default”. ordinary screen. Even if the energy saving
The ECO display setting function is used to set the guidance is turned ON, however, it is not
display of the ECO gauge and energy saving guid- displayed if the condition for display is not
ance. satisfied on the ordinary screen.
1. Selecting menu
Select “Default” on the “Service Menu” screen.
a Display of ECO gauge (a)

“ECO Display” with the function switches or
a Display of energy saving guidance
3. Selecting display setting

After the “ECO Display” screen is displayed,
select the setting with the function switches.
q ON : Display ECO
q OFF: Do not display ECO
q [F3] : Move to left item
q [F4] : Move to right item
q [F5] : Cancel setting before confirmation
and return to “Default” screen
q [F6] : Confirm selection in each line
a After confirming the setting of the upper
and lower lines with [F6], return to the
“Default” screen with [F5], and the setting
is effective.
PC2000-8 43
Adjustment (Pump Absorption Torque) 3. Selecting absorption torque

The operator can adjust various items related to the After the “Pump Absorption Torque (F)” screen
machine with the machine monitor. is displayed, select a set value on the right side
The pump absorption torque (F) function is used to with the function switches.
finely adjust the absorption torque on the front side q Set value: For actual torque adjustment
of the hydraulic pump. value, see table
q [F3]: Increase set value
1. Selecting menu q [F4]: Decrease set value
Select “Adjustment” on the “Service Menu” screen. q [F6]: Confirm setting and return to Adjust-
ment menu screen
a The 3 digits on the left side do not vary
since they are the code of this function.

After the “Adjustment” screen is displayed,
select “Pump Absorption Torque (F)” with the
function switches or numeral input switches. a Relationship between set value and
a Select this item similarly to an item on the torque adjustment value
“Service Menu” screen. Set
Code Torque adjustment value
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 –9.8 Nm {–1 kgm}
006 –19.6 Nm {–2 kgm}
007 –29.4 Nm {–3 kgm}
008 –39.2 Nm {–4 kgm}
44 PC2000-8
For the adjustment items, codes and set values, see the following table.
Item Code Default Set value Adjustment value
Main pump absorption torque 022 000 40.0 kgm
001 30.0 kgm
002 20.0 kgm
003 10.0 kgm
Q 004 0.0 kgm
005 –10.0 kgm
006 –20.0 kgm
007 –30.0 kgm
008 –40.0 kgm
Auto grease pump discharge pressure adjustment 080 000 20 kg/cm2
001 15 kg/cm2
002 10 kg/cm2
003 5 kg/cm2
Q 004 0 kg/cm2
005 –5 kg/cm2
006 –10 kg/cm2
007 –15 kg/cm2
008 –20 kg/cm2
Auto grease interval setting 081 000 30 min
001 25 min
002 20 min
003 15 min
Q 004 10 min
005 5 min
006 4 min
007 3 min
008 2 min
Auto grease pump operating time adjustment 082 000 5 min
001 4 min
Q 002 3 min
003 2 min
004 1 min
005 45 sec
006 30 sec
After-start first greasing time setting 083 000 5 min
001 4 min
002 3 min
003 2 min
Q 004 1 min
005 45 sec
006 30 sec
PC2000-8 45

Fan speed mode selection 055 Q 000 Normal
001 Fixed to 70% speed
002 Fixed to 100% speed
Radiator fan 100% speed adjustment 056 000 105 rpm
Speed adjustment mode: 100% 001 90 rpm
Set speed: 840 rpm 002 75 rpm
003 60 rpm
004 45 rpm
005 30 rpm
006 15 rpm
Q 007 0 rpm
008 –15 rpm
009 –30 rpm
010 –45 rpm
011 –60 rpm
012 –75 rpm
013 –90 rpm
014 –105 rpm
O/C fan 100% speed adjustment 058 000 105 rpm
003 60 rpm
004 45 rpm
005 30 rpm
006 15 rpm
Q 007 0 rpm
008 –15 rpm
009 –30 rpm
010 –45 rpm
011 –60 rpm
012 –75 rpm
013 –90 rpm
014 –105 rpm
46 PC2000-8

Radiator fan 70% speed adjustment 057 000 105 rpm
003 60 rpm
004 45 rpm
005 30 rpm
006 15 rpm
Q 007 0 rpm
008 –15 rpm
009 –30 rpm
010 –45 rpm
011 –60 rpm
012 –75 rpm
013 –90 rpm
014 –105 rpm
O/C fan 70% speed adjustment 059 000 105 rpm
003 60 rpm
004 45 rpm
005 30 rpm
006 15 rpm
Q 007 0 rpm
008 –15 rpm
009 –30 rpm
010 –45 rpm
011 –60 rpm
012 –75 rpm
013 –90 rpm
014 –105 rpm
PC2000-8 47
Cylinder Cut-Out
Menu Right bank Left bank
The operator can perform “Cylinder Cut-Out” oper-
Specified
ation with the machine monitor. All right All cylinders
01 cylinders are
“Cylinder Cut-Out” operation means to run the cylinders drive are driven
stopped
engine with 1 or more fuel injectors disabled electri-
cally to reduce the number of effective cylinders. Specified
All left All cylinders
02 cylinders are
This operation is used to find out a cylinder which cylinders drive are driven
stopped
does not output power normally (combustion in it is
abnormal). Specified
All right All cylinders
03 cylinders are
cylinders stop are stopped
stopped
1. Selecting menu
Select “Cylinder Cut-Out” on the “Service Specified
All left All cylinders
Menu” screen. 04 cylinders are
cylinders stop are stopped
stopped
2) When “01” (All right cylinder drive) is

selected
q Shaded side is stopped and on the actual
machine, the stopped side is indicated by
light blue and driven side is indicated by
dark blue.
2. Setting of cylinders to be reduced

1) Since the V-type 12 cylinders are divided
into the r ight and l eft bank s for the
reduced cylinder mode operation, the con-
ditions of both banks are specified as fol-
lows.
q The left-bank cylinders are indicated

as L1 – L6 and the right-bank ones as
R1 – R6.
In this case, L1 – L6 can be reduced.
a Since “All right cylinder drive” is
selected, R1 – R6 cannot be
reduced.
48 PC2000-8
3) When “02” (All left cylinder drive) is 4) When “03” (All right cylinder stop) is
selected selected
q Shaded side is stopped and on the actual The screen changes to the reduced cylin-
machine, the stopped side is indicated by der mode operation screen and then injec-
light blue and driven side is indicated by tion is stopped in the order of the groups
dark blue. of R1, R3 and R5 and that of R2, R4 and
a The condition is reverse to “All right L6.
cylinder drive”. 1] Screen displayed while R1, R3 and
R5 are stopped.
q L1 to L6 cylinders are the drive side
(indicated by light blue on the actual
machine). Injection in the crossed cyl-
inders (indicated by gray on the
actual machine) is stopped.
q [F1]: Move selection mark (R) to left

q [F2]: Move selection mark (R) to right
q [F3]: Reset holding
q [F4]: Hold
q [F5]: Return to service menu screen
a This operation may be performed while 2] Screen displayed while R2, R4 and
the engine is running. R6 are stopped.
a When [F6] is pressed, if background (a) of q Injection in the crossed cylinders,
the selected cylinder No. becomes white, which are indicated by gray on the
the cylinder is Cut-Out. actual machine, is stopped.
a If the machine monitor Cut-Out a cylinder q Cylinder No. in the crossed cylinders
but the engine controller cannot Cut-Out is stopped already.
that cylinder, the background (a) of the
cylinder No. becomes yellow.
a One or more cylinders can be Cut-Out.
a In the cylinder Cut-Out operation, the
auto-deceleration function can be
selected. If the auto-deceleration is turned
ON, auto-deceleration monitor (b) is dis-
played.
PC2000-8 49
5) If stopping process of R1 – R6 is com- 4. Function of holding displayed information

pleted, the cursor is displayed and the If [F4] is pressed during the cylinder Cut-Out
en gi ne c an b e s tar te d wi th L1 – L 6 operation, the displayed information is newly
stopped. held (c) (The real-time information is kept dis-
a The above process takes several played on the left side).
seconds to protect the fuel injection While the information is held, if [F3] is pressed,
system. the holding function is reset.
a The holding function is effective, regard-
less of setting of the reduced cylinder
mode operation.
6) When “04” (All left cylinder stop) is

selected
a The condition is reverse to “All right cylin-
der stop”. [Reference]
q If a normally operating cylinder is Cut-Out,
3. Resetting Cut-Out cylinder the following phenomena occur.
When changing a cylinder to be Cut-Out or 1) Lowering of engine speed
when Cylinder Cut-Out operation is finished, 2) Increase of final injection rate com-
select a Cut-Out cylinder to be reset with the mand (quantity)
function switches. q If the engine is running near the high idle,
a This operation may be performed while however, the engine speed may not lower
the engine is running. for the reason of engine control.
a When [F6] is pressed, if background (a) of q In this case, lower the engine speed with
the selected cylinder No. becomes blue, the fuel control dial and judge by increase
the cylinder is reset. of the injection rate command.
a The Cut-Out operation is not automatically
reset after the screen returns to the opera-
tor mode. Accordingly, be sure to perform
the resetting operation after the cylinder
cut-out operation is finished.
50 PC2000-8
No Injection 3. Starting no injection cranking

If the engine is operated after long storage of the If no injection cranking (Fuel injection in no cyl-
machine, it may be worn or damaged because of inders) becomes effective, that is displayed on
insufficient lubrication with oil. To prevent this, the the screen. Under this condition, crank the
function to lubricate the engine before starting it by engine with the starting motor.
cranking it without injecting fuel is installed. a While the screen is changing to the follow-
Set the no-injection cranking while the engine is ing screen, the screen of “Setting is being
stopped. prepared” is displayed.
a Limit the cranking time to 20 seconds to
1. Selecting menu protect the starting motor.
Select “No Injection” on the “Service Menu”
screen.
4. Finishing no injection cranking

After completing the no injection cranking
2. Displaying check screen operation, press [F6], and finish of no injection
If the “No injection” screen is displayed, the cranking is displayed and the screen returns to
machine monitor asks the operator if no injec- the “Service Menu” screen automatically.
tion cranking should be performed. Answer
with the function switch.
q [F5]: Do not perform (Return to Service
menu screen)
q [F6]: Perform
a While the screen is changing to the follow-
ing screen, the screen of “Communication
between controllers is being checked” is
displayed.
PC2000-8 51
5. Prohibiting no injection cranking Fuel Consumption

If the operator tries to perform the no injection This function calculates the hourly fuel consump-
cranking while the engine is running, the mes- tion from the actual fuel consumption in a measur-
sage that the engine is running is displayed ing period and indicates it.
and the no injection cranking is not set effec- 1. Selecting menu
tive. Select “Fuel Consumption” on the “Service
a This function can be selected even while Menu” screen.
the engine is running. If the no injection
cranking is performed, however, the mes-
sage of “Engine is running” is displayed on
the screen.
2. Starting measurement
After the screen of “Fuel Consumption” is dis-
played, start measurement with the function
switches.
q [F1]: Start
q [F2]: Clear
q [F5]: Return to Service menu screen
a When the screen of Fuel consumption is
displayed, if a data is indicated, it is the
data of the previous measurement. This
data is not an obstacle to new measure-
ment and can be reset by pressing [F2].
a If [F1] is pressed, the data is displayed on
the starting date and time side and mea-
surement starts.
a The display unit of the fuel changes

according to the unit set with the default
(unit setting) function.
SI and meter: l/h
inch: gal/h
52 PC2000-8
3. Display and function during measurement Setting of snap shot

Clock mark (a) flashes during measurement. This function sends a snap shot trigger command
a While the fuel consumption is being mea- to the VHMS controller to execute the snap shot.
sured, the operator can work with the 1. Selection of menu
operator mode and other functions. Mea- On the “Service menu” screen, select “Snap
surement is not finished until this screen is shot”.
displayed again and [F1] is pressed (Even
if the starting switch is turned OFF, this
function is kept effective, although fuel
consumption is measured only while the
engine is running).
2. Start of snap shot

After the “Snap shot” screen is displayed,
press the “F1” switch, and the snap shot starts.
a The VHMS controller takes 7 minutes 30
seconds to complete the process. This
time can be checked with the bar graph
4. Finishing measurement and the executing time displayed at the
Press [F1], and measurement is finished and bottom of the screen.
the data are displayed on the finishing date
and time side.
5. Displaying fuel consumption

If the measurement is finished, the hourly fuel
consumption calculated from the fuel con-
sumption calculated by the engine controller
and the elapsed time are displayed.
3. Finish of snap shot

The bar graph becomes full in 7 minutes and
30 seconds. After 5 seconds, the screen
returns to the normal screen automatically and
the snap shot finishes.
If the “F6” switch is pressed, the screen
changes to the service screen.
PC2000-8 53
Setting of PM-clinic
This function is used to perform the PM-clinic ser-
vice
1. Selection of menu
On the “Service menu” screen, select “PM-
clinic”.
a There are 12 PM-clinic screen pages.

q If the “F1” switch is pressed, the next
page is displayed.
q If the “F2” switch is pressed, the pre-
vious page is displayed.
q If the “F4” switch is pressed, the cur-
rent page is held.
q If the “F3” switch is pressed, the cur-
rent page is released.
2. Start of PM-clinic
If a page is displayed and the specified opera-
tion is performed, the measured values of the
displayed items are displayed.
3. Finish of PM-clinic
If the [ ] switch is pressed, the screen
changes to the service screen and the PM-
clinic finishes.
4. For the contents of the 12 pages of the PM-

clinic, see the table in the following page.
54 PC2000-8
Component in
Page Item PM-clinic display item ISO m inch
charge
1/12 1 Engine speed r/min rpm rpm ENG
2 Engine coolant temperature °C °C °F ENG (L/B)
3 Engine oil pressure kPa kg/cm 2
psi PUMP (1)
4 Engine oil temperature °C °C °F ENG
5 PTO oil temperature °C °C °F VHMS
6 Hydraulic oil temperature °C °C °F PUMP (2)
2 Intake air temperature °C °C °F ENG (L/B)
3 R/B 1-3 exhaust temperature °C °C °F VHMS
4 R/B 4-6 exhaust temperature °C °C °F VHMS
5 L/B 1-3 exhaust temperature °C °C °F VHMS
2 Intake air temperature °C °C °F ENG (L/B)
3 L/B common rail pressure MPa kg/cm2 psi ENG
4 L/B boost pressure kPa kg/cm2 psi ENG
5 Boost temperature °C °C °F ENG
2 Ambient temperature °C °C °F VHMS
3 L/B fuel temperature °C °C °F ENG
4 R/B fuel temperature °C °C °F ENG
5 L/B common rail pressure MPa kg/cm 2
psi ENG
6 R/B common rail pressure MPa kg/cm 2
psi ENG
3 Ambient pressure kPa kg/cm 2
psi ENG
4 L/B fuel temperature °C °C °F ENG
5 R/B common rail pressure MPa kg/cm2 psi ENG
6 Blow-by pressure MPa kg/cm2 psi VHMS
3 Ambient pressure kPa kg/cm 2
psi ENG
4 R/B fuel temperature °C °C °F ENG
5 R/B common rail pressure MPa kg/cm 2
psi ENG
6 Blow-by pressure MPa kg/cm 2
psi VHMS
3 P1F pump pressure MPa kg/cm2 psi PUMP (1)
4 P1R pump pressure MPa kg/cm2 psi PUMP (1)
5 P2F pump pressure MPa kg/cm2 psi PUMP (1)
PC2000-8 55
Component in
Page Item PM-clinic display item ISO m inch
charge
3 P1F pump pressure MPa kg/cm 2
psi PUMP (1)
4 P1R pump pressure MPa kg/cm 2
psi PUMP (1)
5 VR1 J/S differential pressure MPa kg/cm 2
psi PUMP (1)
6 VL1 J/S differential pressure MPa kg/cm 2
psi PUMP (1)
psi PUMP (1)
psi PUMP (1)
5 VR2 J/S differential pressure MPa kg/cm 2
psi PUMP (1)
6 VL2 J/S differential pressure MPa kg/cm 2
psi PUMP (1)
psi PUMP (1)
5 P1F pump EPC current mA mA mA PUMP (1)
6 P1R pump EPC current mA mA mA PUMP (1)
psi PUMP (1)
psi PUMP (1)
5 P2F pump EPC current mA mA mA PUMP (1)
6 P2R pump EPC current mA mA mA PUMP (1)
3 O/C fan pulley pressure MPa kg/cm 2
psi PUMP (1)
4 RAD fan pump pressure MPa kg/cm 2
psi PUMP (1)
5 RAD fan pump control EPC current mA mA mA PUMP (1)
6 O/C fan pump control EPC current mA mA mA PUMP (1)
56 PC2000-8
Handling controller voltage circuit 1

1. When disconnecting or connecting a connector
between the engine controller and engine, be
sure to turn the starting switch OFF.
2. If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
PC2000-8 57
SEN02009-00
© 2006 KOMATSU
All Rights Reserved
58
SEN02010-00
PC2000-8

PC2000-8 20001 and up

VHMS controller initial setting procedure ............................................................................................. 2
Precautions for replacing VHMS controller ........................................................................................ 19
Preparation work for troubleshooting of electrical system.................................................................. 25
Pm-clinic service ................................................................................................................................ 27
Measurement procedure .................................................................................................................... 28
PC2000-8 1

VHMS controller initial setting procedure 1
a Equipment used for VHMS controller initial set- 1. Confirmation of machine information,
ting engine information, transmission controller
information and controller information
Symbol Part No. Part name a This confirmation procedure is targeted at
the entire machine.
799-608-3211 Diskette
1 Confirm and record the machine informa-
799-608-3220 Wiring harness tion, engine information, VHMS controller
W Note type PC information and ORBCOMM terminal
Commercially
2
available
(Windows 98/2000/Me/XP), information.
with RS232C terminal
No. Information to be confirmed
a Initial setting of VHMS controller shall be done
according to the following procedure. This 1 Model name
operation is needed prior to a full-scale opera- 2 Machine serial No.
tion of a machine being delivered and assem- 3 Current service meter hour
bled in the field, or prior to resumption of its
4 Engine serial No.
operation after a long time of storage.
a Machine data collected with VHMS controller 5 VHMS controller serial No.
are stored and managed on WebCARE data- 6
ORBCOM terminal serial No.
base. In order to endure smooth data process- [Only for machines equipped with ORBCOMM]
ing on WebCARE , consistency must be
provided among the settings done on VHMS a VHMS controller (1) and ORBCOMM ter-
controller. Inconsistencies in the settings minal (2) are installed in the cab base
obstruct loading of data to WebCARE, ham- inner the distribution board.
pering appropriate use of VHMS data. The ini-
tial setting, therefore, is a must.
a For the installation procedure of the VHMS ini-
tial setting program to a PC, refer to the opera-
tion and maintenance manual being bundled
with the service kit W1.
a In the procedure, service menus of the
machine monitor are used. Thus, it is advis-
able to reference the information contained in
the “Special functions of machine monitor” to
understand their procedure beforehand.
a The initial setting procedure is described in the
“ORBCOMM installation specification” and the
“ORBCOMM-less specification”. When using
the “ORBCOMM installation specification”,
implement the procedures needed for VHMS
alone, bypassing those prepared only for ORB-
COMM installation specification.
a Check each step of the setting work referenc-
ing the “VHMS initial setting work check
sheet”.
a Information such as models shown in the fig-
ures may not be identical with actual ones.
2 PC2000-8
2. Connecting a PC 3. Confirming VHMS controller operation and

a This work is done inside the cab. confirming satellite capturing state
1) Make sure the starting switch is at OFF a This work is done inside the cab.
position. a Confirmation of capturing of the satellite is
k Before connecting or disconnect- done for [ORBCOMM installation specifi-
ing a PC, be sure to turn off the cation].
starting switch. 1) Turn the starting switch ON.
2) Using harness [1] of service kit W1, con- 2) Check the controller for normal operation
nect the PC W2 and download connector referencing 7-segment LED of VHMS con-
C53. troller.
a Then connect the PC to RS232C ter- a VHMS controller is fed with switch
minal. power supply. Thus, its operation is
judged normal if its 7-segment LED
starts flashing while rotating as the
starting switch is turned on and then if
the controller starts counting in the
ascending order.
a Download connector C53 is installed

in the front side of the right stand of
operator seat.
3) Among the 7-segment LED situated in the

right side of VHMS controller, refer to the
one that represents the decimal point to
check whether or not ORBCOMM control-
ler has captured the communication satel-
lite. [ORBCOMM installation specification]
a Check whether or not ORBCOMM
controller is capturing the communi-
cation satellite from VHMS controller.
a It is successfully capturing the satel-
lite when the LED representing the
decimal point in the right side 7-seg-
ment LED is flashing.
PC2000-8 3
a It can be checked with monitoring

function of the machine monitor, too.
4. Starting the VHMS initial setting tool

a This work is done inside the cab (from PC).
1) Turn on the PC power and start the OS.
2) Operating [VHMS initial setting tool] icon on
the PC, start up the VHMS initial setting tool.
Important
a Appearance of the setup screen of
the VHMS setting tool depends its
tool.
5. Initial setting of VHMS controller (Ver. 3. 5.
a When using Ver.3.5.2.1 or older ver-
2. 1 or older version)
sion (CD-ROM), the setting proce-
a This work is done inside the cab (from
dure shall conform to that described
PC).
in Section 5.
a It is prohibited in the initial setting to mod-
a When using an update version
ify the data of service meter [SMR].
(Ver.3.5.2.1 or after), the procedure in
[Machine Information]
Section 6 shall be used.
1) Open [Machine Information] tab.
a It is recommended to download the
a [Data clear and Set up] menu displays
latest VHMS version from WebCARE
[Machine Information] tab first.
to update the currently used version.
2) Check every data for correctness.
(Related material: PARTS & SER-
V IC E O PE RAT IO N T IP S S EK N-
5052)
3) Enter the 10-digit service ID to [Service ID].
a Service ID: 7826117000
4) Select [Data clear and Set up] from
[Select Function] item.
5) Click [OK] button to proceed to the setup
screen.
4 PC2000-8
3) When [Date/Time] information is not appro- 5) As every data in [Machine Information]

priate, correct it in the following manner. has been checked and corrected, press
1] Press [Edit] button in the lower right [Apply] button to settle the setting.
side of [Date/Time] box to display the a As [Apply] button is pressed, a mes-
correction screen. sage confirming above setting will
2] After correcting it to the correct infor- appear on the screen. Check the set-
mation, press [OK] button. ting again and, if the setting is correct,
press [OK] button.
a ORBCOMM installation specification
requires the settlement operation after
[Communication Setting] is completed.
4) When [Machine Information] information is

not appropriate, correct it in the following
manner.
1] Press [Edit] button in the lower right
side of [Machine Information] dialog
box to display the correction screen.
2] After correcting it to the correct infor-
mation, press [OK] button.
[Communication Setting] [ORBCOMM installation

specification only]
a This setting shall be implemented after the
request for station opening has been made
and station of ORBCOMM has been opened.
6) Open [Communication Setting] tab.
7) Check every data for correctness.
PC2000-8 5
8) When modifying the setting of [SHORT 10) When modifying the setting of [Satellite
FAULT HISTORY], employ the following Setting], employ the following procedure.
procedure. 1] Press [Edit] button in the [Satellite
1] Select [SHORT FAULT HISTORY] from Setting] block to display the correc-
the screen and then press [Edit] button tion screen.
in the lower left side of [File Transfer 2] Set the GCC code to the region
Setting] block to display the setup applied and, as setting is completed,
screen. press [OK] button.
2] Correct the setting and, as it is com-
pleted, press [OK] button.
a In the initial setting, select [Occur-
rence] from [Timing] item and then
set the function to ON.
GCC codes and applicable regions

Code Applicable region Code Applicable region
1 America 122 Korea
120 Italy 130 Japan
121 Malaysia
9) When modifying the setting of [SHORT
TREND ANALYSIS], employ the following 11) As every data in [Communication Setting]
procedure. has been checked and corrected, press
1] Select [SHORT TREND ANALYSIS] [Apply] button to settle the setting.
from the screen and then press [Edit] a As [Apply] button is pressed, a mes-
button in the lower left side of [File sage confirming above setting will
Transfer Setting] block to display the appear on the screen. Check the set-
setup screen. ting again and, if the setting is correct,
2] Correct the setting and, as it is compress [OK] button.
pleted, press [OK] button.
a In the initial setting, enter [20h] to
[SMR] and then set the function to
ON.
6 PC2000-8
12) As every data in [Machine Information]

and [Communication Setting] has been
checked and corrected, press [Exit] button
to end [VHMS initial setting tool].
13) After the initial setting of the VHMS con-

troller is completed, initialize the machine
monitor maintenance information, too.
q Maintenance information initialization pro-
cedure
1] While the ordinary screen is dis- 2] When the service menu screen
played, perform the following opera- appears, move the yellow cursor onto
tion with the numeral input switches. "04 Maintenance Mode Change"
q Switch operations: While pressing using [F3] or [F4] and then press [F6].
[4], perform [4] + [1] o [2] o [3] in
order.
a This operation of the switches is
accepted only while the ordinary
screen is displayed.
PC2000-8 7
3] When the maintenance mode change 6. Initial setting of VHMS controller (Ver. 3. 5.
screen appears, move the yellow cur- 2. 1 or later version)
sor onto "99 Use Default Value" using a This work is done inside the cab (from PC).
[F3] or [F4] and then press [F6]. a It is prohibited in the initial setting to mod-
ify the data of service meter [SMR].
1) Select [VHMS Setting] and then press
[Next] button.
2) Select [Set up & All clear] and press [Next]

button.
4] The maintenance information is ini-

tialized.
8 PC2000-8
3) Confirm the machine information and, if 4) Select the time zone.

they are correct, press [Next] button. 5) Enter the local time.
6) When DST (Daylight Saving Time) (or
summer time) is currently used, press
[Next] button.
a Selecting DST advances the clock by
an hour. Thus, correction of the time
is needed again.
a When VHMS has been installed later,

it is required to enter the information
such as [Serial No.].
7) Set the GCC code to the target region of

application and, as setting is completed,
press [Next] button.
GCC codes and applicable regions

Code Applicable region Code Applicable region
1 America 122 Korea
120 Italy 123 Brazil
121 Malaysia 130 Japan
PC2000-8 9
8) If there is no problem in the setting dis- 7. Performing Quick Pm

played last, press [Apply] button. a Perform the following procedure in the cab.
a The Quick Pm means the Pm clinic per-
formed by using the snap shot (manual)
function of the machine monitor.
1) Run the engine at low idle and set the
machine in the following position.
q Swing the boom 90° to right
(with the idler on the front side).
q Set the arm vertically.
q Lower the bucket bottom to the ground
and set it horizontally.
2) Set the switches and lever in the following
positions.
q Working mode switch: P-mode
q Heavy lift switch: ON
q Auto-decelerator switch: ON
q Swing lock switch: OFF
9) A screen message will confirm whether or q PCC lock lever: Free
not the data before the setting is to be 3) Set the machine monitor to display the
saved. If the data is not necessary, select service menu.
[NO]. a For the operating method, see “Spe-
cial function of machine monitor”.
4) On the initial screen of the service menu,

select “10 Snap shot” menu.
10) As correction of the first setting is com-

pleted, press [OK] button to end the pro-
gram.
10 PC2000-8
5) Press the [F1] switch to start the snap shot

operation.
a Before starting the snap shot opera-
tion, understand the operating proce-
dure for the Quick Pm by referring to
“Operating procedure for Quick Pm”.
a The data of 48 items are recorded
and saved for 7 minutes 30 seconds
after the [F1] switch on the machine
monitor is pressed.
a The data are recorded at the intervals
of 10 seconds for the first 5 minutes
and at the intervals of 1 second for
the 2 minutes 20 seconds after the 5
minutes.
a To interrupt the snap shot operation,
press the “ ” switch.
a If the snap shot operation is inter-
rupted, the data collected up to now
are not recorded. In this case, repeat
the operation from the first.
6) Operate the fuel dial, swing lock switch,
both work equipment control levers, and
both travel levers according to the “Oper-
at i n g pr o c ed u r e f o r Q u i c k P m ” a n d
elapsed time.
a The elapsed time is displayed on the
machine monitor.
k Since the operator must operate
the work equipment, swing the
boom, and drive the machine actu-
ally for the Quick Pm, take extreme
care of safety around the machine
during the work.
7) After 5 seconds passes since the bar

graph is completed (7 minutes 30 seconds
passes after the snap shot is starts), the
initial screen of the service menu is dis-
played again.
PC2000-8 11
Operating procedure for Quick Pm

*: Operation mode (P)
Time on Fuel Swing lock Data read in Pm clinic after data
No. Elapsed time Operation of lever
snap data dial switch are downloaded
Start 0:00 –330.00 • Engine speed (Low idle)
MIN
1 O O O OFF Set all levers in neutral. • Engine oil pressure (Low idle)
(Low)
Finish 0:30 –300.00 • Ambient temperature
• Engine speed (High idle)
Start 0:30 –300.00 • Engine oil pressure (High idle)
MAX Set all levers in neutral
2 O O O OFF • J/S differential pressure
(High) (Turn decelerator on).
Finish 1:00 –270.00 • Pump oil pressure
• Fan pump oil pressure
Start 1:00 –270.00
MAX Move levers finely [Note]
3 O O O OFF • Engine speed (Auto deceleration)
(High) (Turn decelerator off).
Finish 1:30 –240.00
Start 1:30 –240.00 Raise right-hand track
MAX • Pump pressure
4 O O O OFF shoe and drive it idle
(High) (actuating pressure)
Finish 2:30 –180.00 (Set lever to stroke end).
Swing 180°.
Start 2:30 –180.00
MAX Raise left-hand track shoe • Pump pressure
5 O O O OFF
(High) and drive it idle (Set lever (actuating pressure)
Finish 3:30 –120.00
to stroke end).
Start 3:30 –120.00
MAX • Swing oil pressure
6 O O O ON R.H. swing relief.
(High) (relief pressure)
Finish 4:00 0–90.00
Start 4:00 0–90.00
7 O O O ON L.H. swing relief.
Finish 4:30 0–60.00
Start 4:30 0–60.00
MAX
8 O O O ON Arm OUT relief. • Arm OUT oil pressure
(High)
Finish 5:00 0–30.00
Start 5:00 0–30.00
MAX
9 O O O ON Bucket DUMP relief. • Bucket DUMP oil pressure
(High)
Finish 5:30 0–00.00
Start 5:30 0–00.00
MAX
10 O O O ON Bucket CURL relief. • Bucket CURL oil pressure
(High)
Finish 6:00 0–30.00
Start 6:00 0–30.00
MAX
11 O O O ON Arm IN relief. • Arm IN oil pressure
(High)
Finish 6:30 0–60.00
Start 6:30 0–60.00
MAX
12 O O O ON Boom RAISE relief. • Boom RAISE oil pressure
(High)
Finish 7:00 0–90.00
Start 7:00 0–90.00 Set all levers in neutral
MAX • Engine speed
13 O O O ON (1st deceleration o 2nd
(High) (1st deceleration speed)
Finish 7:30 –120.00 deceleration)
MIN
14 — 7:30 –120.00 ON Finish
(Low)
Note: To turn off the decelerator and set the engine speed to high idle, move one of both work equipment control
levers and both travel levers to a degree that the work equipment does not move or the machine does not
swing or travel. (If the PPC oil pressure switch is turned ON, the auto-decelerator is turned OFF.)
12 PC2000-8
Snap shot item table

No. Item Unit No. Item Unit
Sampling time sec 43 Arm throttle selector valve L —
1 Engine speed rpm 44 Arm throttle selector valve R —
2 Fuel injection rate mm3/st 45 Swing brake valve —
3 Blow-by pressure kPa 46 Swing priority selector valve —
4 Left-bank front exhaust temperature °C 47 Travel back pressure valve —
5 Left-bank rear exhaust temperature °C 48 Swing back pressure valve —
6 Right-bank front exhaust temperature °C
7 Right-bank rear exhaust temperature °C
8 Engine oil pressure MPa
9 engine oil temperature °C
10 Engine coolant temperature °C
11 Intake air pressure kPa
12 Intake air temperature °C
13 Ambient temperature °C
14 Pump 1F oil pressure MPa
15 Pump 1R oil pressure MPa
16 Pump 2F oil pressure MPa
17 Pump 2R oil pressure MPa
18 Fan pump F pressure MPa
19 Fan pump R pressure MPa
20 Hydraulic oil temperature °C
21 Pump 1F control current mA
22 Pump 1R control current mA
23 Pump 2F control current mA
24 Pump 2R control current mA
25 Engine speed command value V
26 Auto-deceleration command value V
27 Fuel injection timing deg
28 Fuel injection pressure MPa
29 PTO oil temperature °C
30 Boom raise oil pressure MPa
31 Boom lower oil pressure MPa
32 Arm in oil pressure MPa
33 Arm out oil pressure MPa
34 Bucket curl oil pressure MPa
35 Bucket dump oil pressure MPa
36 Right travel oil pressure switch —
37 Left travel oil pressure switch —
38 Right swing oil pressure MPa
39 Left swing oil pressure MPa
40 Service valve pressure switch —
41 Straight travel valve —
42 2-stage main relief signal —
PC2000-8 13
8. Download of setting data a Enter [User Name] and [Password].

1) Using harness [1] of service kit W1, con- a For the operating procedure, see the
nect PC W2 to download connector C53 in VHMS analysis tool operation and
the cab or download connector VDL on maintenance manual.
the ground.
3) Using [Download] function, download the

data currently recorded on VHMS to PC.
a For the operating procedure, see the
a Download connector C53 in the cab is VHMS analysis tool operation and
installed in the front side of the right maintenance manual.
stand of operator seat. a After making sure the download is
complete, proceed to the next step.
9. Confirmation of download data

1) Check the setting data using [View] function.
a For the operating procedure, see the
2) Operating [VHMS analysis tool] on PC, VHMS analysis tool operation and
start up the VHMS analysis tool. maintenance manual.
a Make sure that [MFA0] code, which
was used in the quick snapshot, is
indicated in [Fault History].
a Make sure the snap shot data are
recorded.
2) As check of the setting data is finished,

end [VHMS analysis tool].
14 PC2000-8
10. Disconnecting the PC 11. Report to Komatsu

1) Make sure the starting switch is at OFF As steps 1 – 9 are completed, send VHMS/
position. WebCARE setting report to VHMS/WebCARE
k Before connecting or disconnect- Support Center in Komatsu Headquarters.
ing a PC, be sure to turn off the a This report is a must since setting on the
starting switch. receiving end in the satellite communica-
2) End the OS of PC W2 and then turn off the tion must be done by Komatsu.
PC power. a In this case, send VHMS data via Notes
(LAN) or E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
3) When the data was download into the cab,

disconnect harness [1] of service kit W1
from download connector C53.
PC2000-8 15
[For storage] Date of setting:

DB/branch
VHMS initial setting work check sheet office name
Data entered by:
Setup step Check item Result
Model name
Confirmation of machine body and Serial No.
1
component nameplates Engine serial No.
VHMS controller serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
Is “Data Clear and Set up” selected for the setting tool
4 Starting of VHMS initial setting tool yes no
mode?
Is model name identical with machine body? yes no

Initial setting of VHMS controller
Is machine body serial No. correctly entered? yes no
(Setting of machine body informa- Is engine serial No. correctly entered? yes no
5 tion)
In this step, basic machine body Is today's date entered? yes no
information are set on VHMS con- Is current time entered? yes no
troller Is SMR correctly entered? yes no
6 Saving of settings Is LED (7-segment) turned off? yes no
7 Confirmation of VHMS function Is LED operation normal? yes no
Is service mode “SNAPSHOT” turned on and is the

8 Execution of quick Pm yes no
switch hit?
9 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
10 Download Is LED operation normal? yes no
Are all files downloaded? yes no

Hour,
The time downloaded (Reference wrist watch)
minute:
[Confirmation of data]
11 Confirmation of download data
Is [MFA0] error present in Fault History? yes no
Are SMR and time in Fault History consistent with set-
yes no
tings?
Is any data missing in Snap Shot0? yes no
12 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
16 PC2000-8
[For storage] Date of setting:

DB/branch
ORBCOMM station opening work office name
check sheet Data entered by:
Setup step Check item Result
Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
VHMS controller serial No.
ORBCOMM terminal serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
4 Starting of VHMS initial setting tool Is “Set up” selected for the setting tool mode? yes no
Entry of setting to S.Fault History

Initial setting of VHMS controller Presence/absence of communication On Off
1. Setting of communication
(Setting of machine body infor- Number of cases (Default is 8 cases)
mation and PLM are completed) Entry of setting of S.Trend Analysis setting
Presence/absence of communication On Off
Interval (Default is 20H)
5
Entry of setting of S.Payload data
Presence/absence of communication On Off
Tabulation start time
Interval of tabulation (in days) day
2. Setting for start of communica-
Is GCC code set? (130 for Japan) yes no
tion
6 Saving of settings Is LED (7-segment) turned off after data was stored? yes no
How is decimal point display in VHMS monitor

ORBCOMM controller performance
7 (7-segment)? yes no
check
(OFF, ON, long/short flashing)
PC2000-8 17
18 PC2000-8
Precautions for replacing VHMS 2. Confirmation, saving and loading of VHMS

controller 1 controller setting information (Ver. 3. 5. 2. 1
or older version)
a Care should be paid to the following equipment a This work is done inside the cab (from PC).
when replacing VHMS controller a Setting information is saved from the
VHMS controller to be replaced to the PC
Symbol Part No. Part name and the saved information is loaded to the
799-608-3211 Diskette new VHMS controller after the replace-
1 ment.
799-608-3220 Wiring harness
2-1. Confirmation and saving of VHMS controller
W Note type PC
Commercially setting information prior to replacement
2 (Windows 98/2000/Me/XP), 1) Connect the PC and start the VHMS initial
available
with RS232C terminal setting tool.
a See the “VHMS controller initial set-
a When it is required to replace a VHMS control- ting procedure” for this operation.
ler, setup of the replacing VHMS controller 2) Select [Save/Load] and press [OK] button.
shall be conducted before and after the
replacement according to the following proce-
dure.
a Machine data collected with VHMS controller
are stored and managed on WebCARE data-
base. In order to endure smooth data process-
ing on WebCARE , consistency must be
provided among the settings done on VHMS
controller. Inconsistencies in the settings
obstruct loading of data to WebCARE, ham-
pering appropriate use of VHMS data. Setting
work after replacement, therefore, is a must.
a Check each step of the setting work referenc-
ing the “VHMS initial setting work check
sheet”.
a Information such as models shown in the fig-
ures may not be identical with actual ones.
[Operations needed prior to replacement of

VHMS controller]
1. Download of the remaining data
a Using [Download] function, download the 3) Confirm every information before the
currently recorded and remained data on replacement.
VHMS to PC. 4) Select [Save] from [File] of the menu.
a For the operating procedure, refer to “8.
Download of setting data” in “VHMS con-
troller initial setting procedure”.
PC2000-8 19
3) Select [Load] from [File] of the menu.
5) Reconfirm the information and then press

[OK] button to save the information. 4) Currently saved information will be dis-
6) Select [Exit] from [File] of the menu to end played. Press [OK] button.
the VHMS setting tool.
7) Disconnect the PC.
a Refer to “10. Disconnecting the PC” in
“VHMS controller initial setting proce-
dure”.
8) Turns the PC power off.
9) Proceed to replacement of VHMS control-
lers.
2-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
ting procedure” for this operation.
2) Select [Save/Load] and press [OK] button.
5) Display the saved information on another

screen.
6) Press [Edit] button and adjust the time.
20 PC2000-8
7) After adjusting time, press [OK] button. 9) The confirmation screen will ask whether
or not the data before the above setup is
to be saved. Press [NO] button.
a It is not necessary to save the data before
the setting.
8) Press [Apply] button to display contents of

the setting. Check the setting again and, if
it is acceptable, press [OK] button.
10) The setup result is displayed. Confirm the

contents and press [Close] button.
11) Select [Exit] from [File] of the menu to end

the VHMS initial setting tool.
PC2000-8 21
3. Confirmation, saving and loading of VHMS 4) Confirm every information before the
controller setting information (Ver. 3. 5. 2. 1 replacement and then press [Save] but-
or later version) ton.
a Setting information is saved from the VHMS
controller to be replaced to the PC and the
saved information is loaded to the new
VHMS controller after the replacement.
3-1. Confirmation of VHMS controller setting infor-
mation prior to replacement
1) Connect the PC and start the VHMS initial
setting tool.
ting procedure” for this operation.
2) Select [When VHMS needs to be replaced]
and then press [Next] button.
5) Select [Exit] from [File] of the menu to end

the VHMS initial setting tool.
6) Disconnect the PC.
a Refer to “10. Disconnecting the PC” in
“VHMS controller initial setting proce-
dure”.
7) Turns the PC power off.
8) Proceed to replacement of VHMS control-
lers.
3-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
3) Select [Save current setting before initial setting tool.
replacement of VHMS controller] and a See the “VHMS controller initial set-
press [Next] button. ting procedure” for this operation.
2) Select [When VHMS needs to be
replaced] and then press [Next] button.
22 PC2000-8
3) Select [Use previous setting after replace- 6) The confirmation screen will ask whether
ment of VHMS controller] and press [Next] or not the data before the above setup is
button. to be saved. Press [NO] button.
a It is not necessary to save the data
before the setting.
4) Currently saved information will be dis-

played. Press [Next] button.
7) The above completes modification of the

setting. Press [OK] button to end the
VHMS initial setting tool.
5) Adjust the time and press [Apply] button.
PC2000-8 23
[Operations needed after replacement of VHMS

controller]
a Execute the quick Pm referring “7. Executing
quick Pm” in “VHMS controller initial setting
procedure”.
a Download the data referring “8. Download of
setting data” in “VHMS controller initial setting
procedure”.
a After the replacement, send VHMS/WebCARE
setting report sheet to VHMS/WebCARE Sup-
port Center in Komatsu Headquarters.
a Also send two sets of data, the downloaded
before and after the VHMS replacement, via
Notes (LAN) or E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
24 PC2000-8
Preparation work for 2. Engine controller

troubleshooting of electrical 1) Remove controller cover (3).
q Left bank
system 1
a When carrying out troubleshooting of an elec-

tric circuit related to the machine monitor,
engine controller, or VHMS controller, expose
the related connectors according to the follow-
ing procedure.
1. Machine monitor
1) Remove controller cover on the rear side
of machine monitor.
2) Insert or connect troubleshooting T-adapt-
ers in or to connectors CM01 and CM02
on the rear side of machine monitor (1).
q Right bank

ers in or to connectors ENG, CE05 and
CE06 of right bank engine controller (1).
q Right bank
PC2000-8 25
3. Pump controller
1) Remove the controller cover bolts and
controller cover in the operator's cab.
ers in or to connectors CP01, CP02 and
CP03 of pump controller 1.
ers in or to connectors CP04, CP05 and
CP06 of pump controller 2.
4. VHMS controller
1) Open the distribution board cover.
ers in or to connectors CV01, CV02A,
CV02B, CV03A, CV04A and CV04B of the
VHMS controller (1).
26 PC2000-8
Pm-clinic service 1
PC2000-8 27
Measurement procedure 1 3. Measurement procedure by oil pressure

gauge, fan tachometer, etc.
Outline of measurement procedure for PM- Measure each data with an oil pressure gauge,
clinic fan tachometer, etc.
There are the following 3 types of measurement
procedure for PM clinic of PC2000-8. 4. Measurement procedure by downloading
a Basically, apply measurement procedure 1 or data in VHMS controller
2. Connect a personal computer to the VHMS
controller and execute the quick PM clinic with
1. Measurement procedure by machine moni- the machine monitor, and then download the
tor PM clinic data to the personal computer.
Read the data on the PM clinic screen with a The following tools are necessary to this
“PM clinic function” of the machine monitor. measurement procedure.

799-608-3211 • Diskette
1
790-608-3220 • Wiring harness
W Notebook personal computer
Commercially
2 OS: Windows98/2000/Me/XP
available
with “RS232C terminal”
2. Measurement procedure by stopwatch,

scale, etc.
Measure each data with a stopwatch, scale,
etc.
28 PC2000-8
Preparation for measurement for PM clinic Measurement procedure by machine monitor

1. Check safety around the machine and start the 1. Start of engine
engine. 1) Check that the machine monitor is not dis-
playing the abnormality screen.
2. Set the machine monitor to display the service 2) Prepare the PM clinic sheet. Check safety
menu selection screen, and then select the around the machine, sound the horn, and
“PM clinic” menu and display “PM clinic (1/12)” start the engine.
screen. 3) Turn the swing lock switch in the OFF
a For the operating method, see “Testing position.
an d a dj u s t i ng , Sp ec i a l f un c t i on s o f 4) Set the lock lever in the FREE position.
machine monitor”
2. Check of indication of engine coolant tem-
perature gauge and PTO oil temperature
gauge
1) Set the machine monitor to display the
monitor screen (1/2).
2) Check the indication of the engine coolant
temperature gauge and PTO oil tempera-
ture gauge.
3. Warm up the engine to increase the engine

coolant temperature and hydraulic oil tempera-
ture.
q Engine coolant temperature: Min. 40ºC
q Hydraulic oil temperature: Min. 40ºC
4. Stop the machine on a level ground.
5. Prepare for locking the travel system.

k When measuring the travel relief pres-
sure, lock the sprocket on the side to
be measured.
k When measuring the no-load travel
speed, push up the track shoe on the
side to be measured.
6. Lower the work equipment to the ground and

stop the engine.
PC2000-8 29
3. Change of display of machine monitor 5. Measuring with “PM clinic (2/12)”

Set the machine monitor to display the service 1) Display “PM clinic (2/12)”.
menu and select the “PM clinic” menu. 2) Measure the engine speed, intake air
a For the operating method, see “Functions pressure and exhaust temperature (at the
and operation of machine monitor”. front and rear of the right bank and left
bank).
a For the measurement conditions, see
the check sheet.
4. Measuring with “PM clinic (1/12)”

1) Display “PM clinic (1/12)”.
2) Measure the engine speed, engine cool-
ant temperature, engine oil pressure, 6. Measuring with “PM clinic (3/12)”
engine oil temperature, PTO oil tempera- 1) Display “PM clinic (3/12)”.
ture and hydraulic oil temperature. 2) Measure the engine speed, intake air tem-
a For the measurement conditions, see perature, left-bank common rail pressure,
the check sheet. left-bank boost pressure and exhaust tem-
perature (at the front of the left bank).
the check sheet.
30 PC2000-8
7. Measuring with “PM clinic (4/12)” 9. Measuring with “PM clinic (6/12)”
1) Display “PM clinic (4/12)”. 1) Display “PM clinic (6/12)”.
2) Measure the engine speed, ambient tem- 2) Measure the engine speed, ambient tem-
perature, left-bank fuel temperature, right- perature, right-bank fuel temperature,
bank fuel temperature and common rail right-bank common rail pressure and
pressure (of the right and left banks). blow-by pressure.
a For the measurement conditions, see a For the measurement conditions, see
the check sheet. the check sheet.
10. Measuring with “PM clinic (7/12)”

8. Measuring with “PM clinic (5/12)” 1) Display “PM clinic (7/12)”.
1) Display “PM clinic (5/12)”. 2) Measure the engine speed, hydraulic oil
2) Measure the engine speed, ambient tem- temperature, P1F pump pressure, P1R
perature, left-bank fuel temperature, left- pump pressure, P2F pump pressure and
bank common rail pressure and blow-by P2R pump pressure.
pressure. a For the measurement conditions, see
a For the measurement conditions, see the check sheet.
the check sheet.
PC2000-8 31
1) Display “PM clinic (8/12)”. 1) Display “PM clinic (10/12)”.
2) Measure the engine speed, hydraulic oil 2) Measure the engine speed, hydraulic oil
temperature, P1F pump pressure, P1R temperature, P1F pump pressure, P1R
pump pressure, VR1 J/S differential pres- pump pressure, P1F pump control EPC
sure and VL1 J/S differential pressure. current and P1R pump control EPC cur-
a For the measurement conditions, see rent.
the check sheet. a For the measurement conditions, see
the check sheet.
1) Display “PM clinic (9/12)”.
2) Measure the engine speed, hydraulic oil 1) Display “PM clinic (11/12)”.
temperature, P2F pump pressure, P2R 2) Measure the engine speed, hydraulic oil
pump pressure, VR2 J/S differential pres- temperature, P2F pump pressure, P2R
sure and VL2 J/S differential pressure. pump pressure, P2F pump control EPC
a For the measurement conditions, see current and P2R pump control EPC cur-
the check sheet. rent.
the check sheet.
32 PC2000-8
15. Measuring with “PM clinic (12/12)” 17. Measuring fan speed
1) Display “PM clinic (12/12)”. Using a tachometer, measure the RAD and O/C
2) Measure the engine speed, ambient tem- fan speeds.
perature, fan pump pressure (O/C), fan a See “Testing and adjusting (Part 2)”, Mea-
pump pressure (RAD), fan pump control suring fan speed.
EPC (RAD) current and fan pump control
EPC (O/C) current
the check sheet.
16. Measuring PPC basic pressure

a For the measurement conditions, see the
check sheet.
a Connect a pressure gauge to the PPC
basic pressure pickup coupler to measure
the PPC basic pressure.
18. Measuring work equipment speed and

hydraulic drift
Using a stopwatch, scale, etc., measure the
work equipment speed and hydraulic drift.
PC2000-8 33
Measurement procedure by download- 3. Change of display of machine monitor

ing data in VHMS controller 1) Set the machine monitor to display the
1. Connection of personal computer service menu selection screen.
1) Check that the starting switch is in the a See “Functions and operation of
OFF position. machine monitor”.
k Be sure to connect and disconnect
2) Select “Snap shot”.
the personal computer while start-
ing switch is in the OFF position.
2) Connect personal computer W2 and
download connector C53 by wiring har-
ness [1] of service kit W1.
a Download connector C53 is installed
to the top of the left console.
a Connect the personal computer to the
RS232C terminal.
4. Execution of snap shot

1) Continue the operation on the screen to
start the snap shot.
a While the screen at right is displayed,
press the F1 button, and the check
message is displayed.
a Before starting the snap shot, fully
understand the operating procedure
for the snap shot.
2. Start of engine
1) Check that the machine monitor is not dis-
playing the abnormality screen.
2) Prepare the PM clinic sheet. Check safety
around the machine, sound the horn, and
start the engine.
3) Turn the swing lock switch in the OFF
position.
4) Set the PPC lock lever in the FREE posi-
tion.
34 PC2000-8
2) Operate the switches and levers at each

execution time according to the “Operat-
ing procedure for quick PM clinic” shown
in the following table.
a The execution times are displayed on
the machine monitor.
k Since the work equipment and
machine are operated actually dur-
ing the quick PM clinic, take care of
the safety around the machine
extremely during the work.
PC2000-8 35
Operating procedure for Quick Pm

Time on Fuel Swing lock Data read in Pm clinic after data
No. Elapsed time Operation of lever
snap data dial switch are downloaded
Start 0:00 –330.00 • Engine speed (Low idle)
MIN
1 O O O OFF Set all levers in neutral. • Engine oil pressure (Low idle)
(Low)
Finish 0:30 –300.00 • Ambient temperature
• Engine speed (High idle)
Start 0:30 –300.00 • Engine oil pressure (High idle)
MAX Set all levers in neutral
2 O O O OFF • J/S differential pressure
(High) (Turn decelerator on).
Finish 1:00 –270.00 • Pump oil pressure
• Fan pump oil pressure
Start 1:00 –270.00
MAX Move levers finely [Note]
3 O O O OFF • Engine speed (Auto deceleration)
(High) (Turn decelerator off).
Finish 1:30 –240.00
Start 1:30 –240.00 Raise right-hand track
MAX • Pump pressure
4 O O O OFF shoe and drive it idle
(High) (actuating pressure)
Finish 2:30 –180.00 (Set lever to stroke end).
Swing 180°.
Start 2:30 –180.00
MAX Raise left-hand track shoe • Pump pressure
5 O O O OFF
(High) and drive it idle (Set lever (actuating pressure)
Finish 3:30 –120.00
to stroke end).
Start 3:30 –120.00
6 O O O ON R.H. swing relief.
Finish 4:00 0–90.00
Start 4:00 0–90.00
7 O O O ON L.H. swing relief.
Finish 4:30 0–60.00
Start 4:30 0–60.00
MAX
8 O O O ON Arm OUT relief. • Arm OUT oil pressure
(High)
Finish 5:00 0–30.00
Start 5:00 0–30.00
MAX
9 O O O ON Bucket DUMP relief. • Bucket DUMP oil pressure
(High)
Finish 5:30 0–00.00
Start 5:30 0–00.00
MAX
10 O O O ON Bucket CURL relief. • Bucket CURL oil pressure
(High)
Finish 6:00 0–30.00
Start 6:00 0–30.00
MAX
11 O O O ON Arm IN relief. • Arm IN oil pressure
(High)
Finish 6:30 0–60.00
• Boom RAISE oil pressure
Start 6:30 0–60.00
MAX • Blow-by pressure
12 O O O ON Boom RAISE relief.
(High) • Exhaust temperature
Finish 7:00 0–90.00
• Boost pressure
Start 7:00 0–90.00 Set all levers in neutral
MAX • Engine speed
13 O O O ON (1st deceleration o 2nd
(High) (1st deceleration speed)
Finish 7:30 –120.00 deceleration)
MIN
14 — 7:30 –120.00 ON Finish
(Low)
Note: To turn off the decelerator and set the engine speed to high idle, move one of both work equipment control
levers and both travel levers to a degree that the work equipment does not move or the machine does not
swing or travel. (If the PPC oil pressure switch is turned ON, the auto-decelerator is turned OFF.)
36 PC2000-8
5. Downloading of snap shot data

1) Turn the personal computer ON and start
the OS.
2) Click the icon of [VHMS Analysis Tool] on
the personal computer to start the VHMS
analysis tool.
a Input [User Name] and [Password].
a For the operation procedures, see the
operation manual for VHMS Analysis
Tool.
3) Use the [Download] function to download

the data recorded in the VHMS controller
to the personal computer.
a For the operation procedures and
data analyzing method, see the oper-
ation manual for VHMS Analysis Tool.
PC2000-8 37
Pm-Clinic service
Chassis serial No.
PC2000-8
Backhoe
Engine serial No. (SAA12V140E-3)
Hour inspection
Work direction No. Date of execution Service meter Inspector
Interview with operator and walk-around inspection Accepted Rejected

Is there any abnormality before starting inspection?
Max. level of (F) coolant temperature Max. (F) PTO oil temperature Ambient temperature
Blue Red Blue Red Max. °C
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
Min. °C
(During work) (During work)
Altitude m
Max. level of (R) coolant temperature Max. (R) PTO oil temperature
Blue Red Blue Red
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
(During work) (During work)
Measurement Standard value Service limit Measurement

Condition Unit Accepted Rejected
items for new machine value result
After starting engine
Engine: Low idle 775 – 875 775 – 875
1-1
Engine: High idle 1930 – 2030 1930 – 2030
Engine: Full throttle
Boom: Raise relief 1680 – 1880 1680 – 1880
Engine
speed Engine: Full throttle rpm
1680 – 1880 1680 – 1880
(in DH mode) Boom: Raise relief + Heavy lift: ON
Auto-deceleration switch: ON
Fuel control dial: Max. 1300 – 1500 1300 – 1500
Control lever: Neutral
1-2 kPa Max. 2.94 Min. 5.88
At rated horsepower
Blow-by pressure {mmAq} {Max. 300} {Min. 600}
1. Engine
1-3 Min. 0.08 Min. 0.06

Engine: Low idle (SAE10)
{Min. 0.8} {Min. 0.6}
Engine Min. 0.08 Min. 0.06
MPa
lubricating oil Engine: Low idle (SAE30)
{kg/cm2} {Min. 0.8} {Min. 0.6}
pressure
0.29 – 0.44 Min. 0.2
Engine: High idle (SAE30)
{3.0 – 4.5} {Min. 2.0}
1-4
kPa Min. 125.7 Limit is
Boost At rated horsepower {mmHg} {Min. 950} not set
pressure
1-5 At all speed range Max. 700 Max. 750
Exhaust °C
temperature Ambient temperature 20 20 — —
Metal powder must not be

2. PTO
2-1 —
Visual check of filter collected.
2-2
Check of center bearing thermo-label 120°C range must not be black.
°C
2-3
PTO oil temperature Max. 120°C Max. 120°C
1. Boom RAISE 6.7 – 8.3 Max. 9.0

2. Boom
4.8 – 5.8 Max. 6.4
3. Work equipment speed
LOWER Engine: Full throttle

3. Arm IN DH mode 6.7 – 8.3 Max. 9.0
4. Arm OUT Hydraulic oil temperature: 45 - 55°C 4.7 – 5.7 Max. 6.2
5. Bucket CURL 4.5 – 5.5 Max. 6.0
sec
Swing: Measure time for
6. Bucket DUMP 5 turns after 1 turn. 3.5 – 4.3 Max. 4.7
7. Swing 5 turns Travel: Raise each track and measure 5 turns 57.5 – 67.5 Max. 70.0
8. Drive right with no load after 1 turn.
track 5 turns 90.5 – 110.5 90.5 – 110.5
9. Drive left
90.5 – 110.5 90.5 – 110.5
track 5 turns
38 PC2000-8
Standard value for Measurement
Measurement items Condition Unit Service limit value Accepted Rejected
new machine result
Set work equipment in measuring posture and stop engine.
Hydraulic drift of Max. 1,200 Max. 1,800
Whole work equipment Work equipment
4 Hydraulic drift
bucket tooth tip {Max. 650} {Max. 1000}

posture: Boom and
arm in level, bucket Max. 60 Max. 90
Boom cylinder Cylinder retraction
curled, rated load on mm/15 {Max. 35} {Max. 50}
work equipment [no min Max. 165 Max. 250
Arm cylinder load] Cylinder extension
{Max. 70} {Max. 105}
Hydraulic oil
temperature: 45 – 55ºC Cylinder retraction Max. 50 Max. 80
Bucket cylinder
{Max. 15} {Max. 30}
Standard value for Service limit value Measurement result Accepted Rejected
Measurement items Condition Unit
new machine F engine R engine
5-1 Control lever:
Control pressure (PPC 3.24 – 3.73 3.04 – 3.73
Neutral {33 – 38} {31 – 38}
basic pressure)
Control lever: Min. 1.28 MPa Min. 1.28 MPa
Neutral {Min. 13.1 kg/cm2} {Min. 13.1 kg/cm2}
Right travel lever: MPa
5-2 Stroke end {kg/cm2} Max. 0.17 MPa Max. 0.17 MPa
Jet sensor differential Track: Turning with {Max. 1.7 kg/cm2} {Max. 1.7 kg/cm2}
pressure no load
Left travel lever:
Stroke end Max. 0.17 MPa Max. 0.17 MPa
Track: Turning with {Max. 1.7 kg/cm2} {Max. 1.7 kg/cm2}
no load
Control lever: 160 – 280 160 – 280
Neutral
Right travel lever:
Stroke end P1 : 390 – 510 P1 : 390 – 510
5-3 Track: Turning with P2 : 615 – 735 P2 : 615 – 735
mA
Pump EPC current no load
Left travel lever:
Stroke end P1 : 390 – 510 P1 : 390 – 510
Track: Turning with P2 : 615 – 735 P2 : 615 – 735
no load
Boom: Raise relief 28.4 – 30.4 27.4 – 30.4
(Normal) {290 – 310} {280 – 310}
(Heavy lift ON) {317 – 337} {307 – 337}
28.4 – 30.4 27.4 – 30.4
Arm: In relief
5-4 {290 – 310} {280 – 310}
P1F pump pressure 28.4 – 30.4 27.4 – 30.4
Arm: Out relief
{290 – 310} {280 – 310}
28.4 – 30.4 27.4 – 30.4
Bucket: Curl relief
{290 – 310} {280 – 310}
Swing: Relief 28.4 – 30.4 27.4 – 30.4
{290 – 310} {280 – 310}
Hydraulic oil
5 Hydraulic system
temperature: 45 – 55ºC Boom: Raise relief 28.4 – 30.4 27.4 – 30.4

Mode: P (Normal) {290 – 310} {280 – 310}
Engine: Full throttle Boom: Raise relief 31.1 – 33.1 30.1 – 33.1
Fan: 100% speed mode (Heavy lift ON) {317 – 337} {307 – 337}
5-5 Auto-decelerator: OFF 28.4 – 30.4 27.4 – 30.4
P1R pump pressure Arm: In relief {290 – 310} {280 – 310}
28.4 – 30.4 27.4 – 30.4
Arm: Out relief
MPa {290 – 310} {280 – 310}
{kg/cm2} 28.4 – 30.4 27.4 – 30.4
Bucket: Curl relief
{290 – 310} {280 – 310}
(Normal) {290 – 310} {280 – 310}
(Heavy lift ON) {317 – 337} {307 – 337}
5-6 28.4 – 30.4 27.4 – 30.4
P2F pump pressure Arm: In relief
{290 – 310} {280 – 310}
28.4 – 30.4 27.4 – 30.4
Arm: Out relief
{290 – 310} {280 – 310}
28.4 – 30.4 27.4 – 30.4
Bucket: Curl relief
{290 – 310} {280 – 310}
(Heavy lift ON) {317 – 337} {307 – 337}
28.4 – 30.4 27.4 – 30.4
Arm: In relief
5-7 {290 – 310} {280 – 310}
P2R pump pressure 28.4 – 30.4 27.4 – 30.4
Arm: Out relief
{290 – 310} {280 – 310}
28.4 – 30.4 27.4 – 30.4
Bucket: Curl relief
{290 – 310} {280 – 310}
5-8
Control lever: STD : 575 – 675 STD : 575 – 675
Fan pump EPC
Neutral 55ºC : 505 – 605 55ºC : 505 – 605
(Radiator) current
mA
5-9
Fan pump EPC (Oil Control lever: STD : 600 – 700 STD : 600 – 700
Neutral 55ºC : 505 – 605 55ºC : 505 – 605
cooler) current
5-10 Control lever: STD : 790 – 890 STD : 790 – 890
Fan speed (Radiator) Neutral 55ºC : 1050 – 1150 55ºC : 1050 – 1150
rpm
5-11 Control lever: STD : 710 – 810 STD : 710 – 810
Fan speed (Oil cooler) Neutral 55ºC : 1050 – 1150 55ºC : 1050 – 1150
5-12 Mode: P
Hydraulic oil Engine: Full throttle Bucket: Dump relief ºC Max. 100ºC Max. 100ºC
temperature Fan: 100% speed mode
PC2000-8 39
There must not be excessive metal powder or
Visual check of hydraulic tank strainer (Every 2,000 H)
6 foreign matter.
Memo: Enter phenomena and information you noticed during today's check.
40 PC2000-8
Pm-Clinic service PC2000-8
Visual check of welded structures (For PC2000-8)

If any crack is found, draw its shape below.
Arm Boom Revolving frame

1. Arm cylinder bracket 5. Boom top bracket 9. Boom bracket
Left Right Left Right Left Right
2. Arm foot 6. Boom cylinder bracket
Left Right End plate Left Right Track frame
3. Arm top boss 7. Boom lower plate
10. Circle bracket
Left Right Left Right
Front Rear
4. Arm cylinder bracket 8. Boom foot
Left Right
Left Right Left Right
11. Track frame mounting section
Front Rear
Left Right
PC2000-8 41
SEN02010-00
© 2006 KOMATSU
All Rights Reserved
42
SEN02011-00
PC2000-8

PC2000-8 20001 and up
40 Troubleshooting 1
Failure code table and fuse locations
Failure code table................................................................................................................................. 2
Before carrying out troubleshooting of electrical system...................................................................... 9
PC2000-8 1
SEN02011-00 40 Troubleshooting
Failure code table and fuse locations 1

Failure code table 1
User Applicable History Reference

code equipment classification document No.
0410KA Fuel LV. Sensor Failure — MON Electrical system
0410KB Fuel LV. Sensor Failure — MON Electrical system
6014NX
Hydraulic Oil Filter Clogging — VHMS Mechanical system
[n5o51]
8800ZG Auto grease abnormally — PUMP Mechanical system
7@HAZL VR1/P1F Relief Press Abnormality — PUMP Mechanical system
7@HBZL VL1/P1R Relief Press Abnormality — PUMP Mechanical system
7@HCZL VR2/P2F Relief Press Abnormality — PUMP Mechanical system
7@HDZL VL2/P2R Relief Press Abnormality — PUMP Mechanical system
AA10NX Aircleaner Clogging — MON Mechanical system
AB00KE Change Voltage Low — MON Mechanical system
aB00KE VHMS
Low Upper ALR Charge Voltage — VHMS
[n9o11] [n9o11]
B@BAZG Eng. Oil Press. Low — ENG Mechanical system
B@BAZK Eng. Oil Level Low — MON Mechanical system
B@BCNS Eng. Water Overheat — ENG Mechanical system
B@BCZK Eng. Water Lvl Low — MON Mechanical system
B@CBNS VHMS
PTO Oil Overheat — PUMP
[n5o61] [n5o61]
Troubleshooting
B@HANS Hydr. Oil Overheat — MON Mechanical system
by failure code,
B@HAZK VHMS Part 1
Low Hydraulic Oil Level — VHMS
[n5o52] [n5o52] SEN02096-00
CA111 ECM Critical Internal Failure E10 ENG Electrical system
CB111 ECM Critical Internal Failure E10 ENG Electrical system
CA115 Eng. Ne and Bkup Speed Sens Error E10 ENG Electrical system
CB115 Eng. Ne and Bkup Speed Sens Error E10 ENG Electrical system
CA122 Chg Air Press Sensor High Error E11 ENG Electrical system
CA123 Chg Air Press Sensor Low Error E11 ENG Electrical system
CA131 Throttle Sensor High Error E14 ENG Electrical system
CA132 Throttle Sensor Low Error E14 ENG Electrical system
CA135 Eng Oil Press Sensor High Error E15 ENG Electrical system
CA141 Eng Oil Press Sensor Low Error E15 ENG Electrical system
CA144 Coolant Temp Sens High Error E15 ENG Electrical system
CA145 Coolant Temp Sens Low Error E15 ENG Electrical system
CA153 Chg Air Temp Sensor High Error E15 ENG Electrical system
CA154 Chg Air Temp Sensor Low Error E15 ENG Electrical system
CA212 Eng Oil Temp Sensor High Error E15 ENG Electrical system
CA213 Eng Oil Temp Sensor Low Error E15 ENG Electrical system
2 PC2000-8

CA221 Ambient Press Sens High Error E15 ENG Electrical system
CA222 Ambient Press Sens Low Error E15 ENG Electrical system
CA234 Eng Over Speed E15 ENG Electrical system
CA238 Ne Speed Sens Supply Volt Error E15 ENG Electrical system
CB238 Ne Speed Sens Supply Volt Error E15 ENG Electrical system
CA263 Fuel Temp Sensor High Error E15 ENG Electrical system
CB263 Fuel Temp Sensor High Error E15 ENG Electrical system
CA265 Fuel Temp Sensor Low Error E15 ENG Electrical system
CB265 Fuel Temp Sensor Low Error E15 ENG Electrical system
CA271 IMV/PCV1 Short Error E10 ENG Electrical system
CB271 IMV/PCV1 Short Error E10 ENG Electrical system
CA272 IMV/PCV1 Open Error E10 ENG Electrical system
CB272 IMV/PCV1 Open Error E10 ENG Electrical system
CA273 PCV2 Short Error E10 ENG Electrical system
CB273 PCV2 Short Error E10 ENG Electrical system
CA274 PCV2 Open Error E10 ENG Electrical system
CB274 PCV2 Open Error E10 ENG Electrical system Troubleshooting
by failure code,
Part 2
CA323 Inj #5(L#5) Open/Short Error E11 ENG Electrical system SEN02097-00
CA342 Calibration Code Incompatibility E10 ENG Electrical system
CB342 Calibration Code Incompatibility E10 ENG Electrical system
CA351 Injectors Drive Circuit Error E10 ENG Electrical system
CB351 Injectors Drive Circuit Error E10 ENG Electrical system
CA441 Battery Voltage Low Error E10 ENG Electrical system
CB441 Battery Voltage Low Error E10 ENG Electrical system
CA442 Battery Voltage High Error E10 ENG Electrical system
CB442 Battery Voltage High Error E10 ENG Electrical system
CA449 Rail Press Very High Error E11 ENG Electrical system
CB449 Rail Press Very High Error E11 ENG Electrical system
PC2000-8 3

CA451 Rail Press Sensor High Error E11 ENG Electrical system
CB451 Rail Press Sensor High Error E11 ENG Electrical system
CA452 Rail Press Sensor Low Error E11 ENG Electrical system
CB452 Rail Press Sensor Low Error E11 ENG Electrical system
CA553 Rail Press High Error E15 ENG Electrical system
CB553 Rail Press High Error E15 ENG Electrical system
CA554 Rail Press Sensor In Range Error E11 ENG Electrical system
CB554 Rail Press Sensor In Range Error E11 ENG Electrical system
CA559 Rail Press Low Error E15 ENG Electrical system
CB559 Rail Press Low Error E15 ENG Electrical system
CA689 Eng Ne Speed Sensor Error E15 ENG Electrical system
CB689 Eng Ne Speed Sensor Error E15 ENG Electrical system
CA691 Intake Air Temp Sens High Error E15 ENG Electrical system
CA692 Intake Air Temp Sens Low Error E15 ENG Electrical system
CA731 Eng Bkup Speed Sens Phase Error E15 ENG Electrical system
CB731 Eng Bkup Speed Sens Phase Error E15 ENG Electrical system
CA757 All Persistent Data Lost Error E10 ENG Electrical system
CB757 All Persistent Data Lost Error E10 ENG Electrical system
CA778 Eng Bkup Speed Sensor Error E15 ENG Electrical system Troubleshooting
by failure code,
CB778 Eng Bkup Speed Sensor Error E15 ENG Electrical system
Part 3
CA781 CEN Communication Error E0E ENG Electrical system SEN02098-00
CB781 CEN Communication Error E0E ENG Electrical system
CA1117 Persistent Data Lost Error E10 ENG Electrical system
CB1117 Persistent Data Lost Error E10 ENG Electrical system
CA1257 Harness Key Error E0E ENG Electrical system
CB1257 Harness Key Error E0E ENG Electrical system
CA1633 KOMNET Data link Time out Error E0E ENG Electrical system
CA2185 Throt Sens Sup Volt High Error E14 ENG Electrical system
CA2186 Throt Sens Sup Volt Low Error E14 ENG Electrical system
CA2249 Rail Press Very Low Error E11 ENG Electrical system
CB2249 Rail Press Very Low Error E11 ENG Electrical system
CA2555 Grid Heater Relay Volt Low Error E15 ENG Electrical system
CA2556 Grid Heater Relay Volt High Error E15 ENG Electrical system
4 PC2000-8

D110KB Battery Relay Drive S/C — PUMP Electrical system
D163KB Flash Light Relay S/C — PUMP Electrical system
D195KA Step Light Relay Disc — PUMP Electrical system
D195KY Step Light Relay S/C — PUMP Electrical system
D1E9KB Wiper Drive Relay 1 S/C — PUMP Electrical system
D1EAKB Wiper Drive Relay 2 S/C — PUMP Electrical system
D1EBKB Low Wiper Brake Relay Short Circuit — PUMP Electrical system
D1ECKB Upper Wiper Brake Relay Short Circuit — PUMP Electrical system
DA22KK Pump 1 Solenoid Power Low Error E0E PUMP Electrical system
dA22KK Pump 2 Solenoid Power Low Error E0E PUMP Electrical system
DA25KP Pump 1 Sens Supply Vol Low Error E07 PUMP Electrical system
dA25KP Pump 2 Sens Supply Vol Low Error — PUMP Electrical system
DA26KP 5V Sensor 2 Power Abnormality E07 PUMP Electrical system
DA29KQ Pump 1 Model Select Abnormality — PUMP Electrical system
dA29KQ Pump 2 Model Select Abnormality — PUMP Electrical system Troubleshooting
DA2RMC CAN Discon (Pump 1 Con Detected) E0E PUMP Electrical system by failure code,
Part 4
dA2RMC CAN Discon (Pump 2 Con Detected) E0E PUMP Electrical system SEN02099-00
DA2TMC Pump Comm. ECM Child Abnormality — PUMP Electrical system
DBB0KK VHMS
VHMS Source Voltage Error — VHMS
[n9o01] [n9o01]
DBB0KQ VHMS
VHMS Connector Mismatch — VHMS
[nFo11] [nFo11]
DBB5KP VHMS
VHMS 5V source sys Error — VHMS
[n9o04] [n9o04]
DBB6KP VHMS
VHMS 24V source sys Error — VHMS
[n9o02] [n9o02]
DBBQKR VHMS
KOM-NET/c error — VHMS
[n8o02] [n8o02]
DGE5KX VHMS
Ambient Air Temp Sensor Failure — VHMS
[n4o01] [n4o01]
DGH2KB Hydr. Oil Temp. Sensor S/C — PUMP Electrical system
DGT3KZ VHMS
PTO Temp Sensor Failure — VHMS
[n5o01] [n5o01]
PC2000-8 5

DGT5KA VHMS
Exhaust Temp. Sensor LBF Failure — VHMS
[n3o12] [n3o12]
dGT5KA VHMS
Exhaust Temp. Sensor LBR Failure — VHMS
[n3o22] [n3o22]
DGT5KB VHMS
Exhaust Temp. Sensor LBF Failure — VHMS
[n3o11] [n3o11]
dGT5KB VHMS
Exhaust Temp. Sensor LBR Failure — VHMS
[n3o21] [n3o21]
DGT6KA VHMS
Exhaust Temp. Sensor RBF Failure — VHMS
[n3o24] [n3o24]
dGT6KA VHMS
Exhaust Temp. Sensor RBR Failure — VHMS
[n3o25] [n3o25]
DGT6KB VHMS
Exhaust Temp. Sensor RBF Failure — VHMS
[n3o23] [n3o23]
dGT6KB VHMS
Exhaust Temp. Sensor RBR Failure — VHMS
[n3o26] [n3o26]
Troubleshooting
DHE5KB VHMS
Blowby Pres. Sensor Failure by failure code,
[n3o32] [n3o32]
Part 5
DHE5KY VHMS SEN02100-00
Blowby Pres. Sensor Failure
[n3o31] [n3o31]
DHH2KA VHMS
Hydraulic oil filter Sensor Failure
[n3o53] [n3o53]
DHPEKX VR1/P1F Pump P. Sensor Abnormality E07 PUMP Electrical system
DHPFKX VL1/P1R Pump P. Sensor Abnormality E07 PUMP Electrical system
DHPGKX VR2/P2F Pump P. Sensor Abnormality E07 PUMP Electrical system
DHPHKX VL2/P2R Pump P. Sensor Abnormality E07 PUMP Electrical system
DHPSKX Auto Grease Press Sensor Abnormality — PUMP Electrical system
DHPTKX Fan(RAD) Pump P. Sensor Open Circuit — PUMP Electrical system
DHPUKX Fan(O/C) Pump P. Sensor Open Circuit — PUMP Electrical system
DHS3KX Arm Dig PPC Press Sensor Abnormality — PUMP Electrical system
DHS4KX Bucket Curl PPC Press Sensor Abnormality — PUMP Electrical system
DHS8KX Boom Raise PPC Press Sensor Abnormality — PUMP Electrical system
DHS9KX Boom Lower PPC Press Sensor Abnormality — PUMP Electrical system
DHSAKX Swing Right PPC Press Sensor Abnormality — PUMP Electrical system
DHSBKX Swing Left PPC Press Sensor Abnormality — PUMP Electrical system
DHSCKX Arm Dump PPC Press Sensor Abnormality — PUMP Electrical system
DHSDKX Bucket Dump PPC Press Sensor Abnormality — PUMP Electrical system
6 PC2000-8

DUM3KB Auto Grease Caution LED Short Circuit — PUMP Electrical system
DUM4KB FAN Reverse LED Short Circuit — PUMP Electrical system
DV20KB Travel Alarm S/C — PUMP Electrical system
DW41KA Swing Priority Sol Open Circuit — PUMP Electrical system
DW41KB Swing Priority Sol Short Circuit — PUMP Electrical system
DW45KA Swing Brake Sol. Disc. E03 PUMP Electrical system
DW45KB Swing Brake Sol. S/C E03 PUMP Electrical system
DW91KA Straight-Travel Sol. Disc. PUMP Electrical system
DW91KB Straight-Travel Sol. S/C — PUMP Electrical system
DW4XKA Bucket Curl Hi Cancel Sol. Disc. — PUMP Electrical system
DW4XKB Bucket Curl Hi Cancel Sol. S/C — PUMP Electrical system
DW7BKA Fan Motor(RAD) Reverse Sol Open Circuit — PUMP Electrical system
DW7BKB Fan Reverse Sol S/C — PUMP Electrical system Troubleshooting
by failure code,
DW7HKA Fan Motor(O/C) Reverse Sol Open Circuit — PUMP Electrical system
Part 6
DW7HKB Fan Motor(O/C) Reverse Sol Short Circuit — PUMP Electrical system SEN02101-00
DWA3KA Arm throttle Valve/L Sol Open Circuit — PUMP Electrical system
DWA3KB Arm throttle Valve/L Sol Short Circuit — PUMP Electrical system
DWA4KA Arm throttle Valve/R Sol Open Circuit — PUMP Electrical system
DWA4KB Arm throttle Valve/R Sol Short Circuit — PUMP Electrical system
DWA5KA Auto Grease Sol Open Circuit — PUMP Electrical system
DWA5KB Auto Grease Sol Short Circuit — PUMP Electrical system
DWA6KA Boom throttle Valve Sol Open Circuit — PUMP Electrical system
DWA6KB Boom throttle Valve Sol Short Circuit — PUMP Electrical system
DWK0KA 2-stage Relief Sol. Disc. — PUMP Electrical system
DWK0KB 2-stage Relief Sol. S/C — PUMP Electrical system
DWK2KA Back Press Comp Valve Sol Open Circuit — PUMP Electrical system
DWK2KB Back Press Comp Valve Sol Short Circuit — PUMP Electrical system
PC2000-8 7

DWN5KA Fan(RAD) Pump Epc Sol Open Circuit E11 PUMP Electrical system
DWN5KB Fan(RAD) Pump Epc Sol Short Circuit E11 PUMP Electrical system
DWNCKA Fan(O/C) Pump Epc Sol Open Circuit E11 PUMP Electrical system
DWNCKB Fan(O/C) Pump Epc Sol Short Circuit E11 PUMP Electrical system
DXAAKA P1F EPC Sol Disc E07 PUMP Electrical system
DXAAKB P1F EPC Sol S/C E07 PUMP Electrical system
DXABKA P1R EPC Sol Disc E07 PUMP Electrical system
DXABKB P1R EPC Sol S/C E07 PUMP Electrical system
DXACKA P2F EPC Sol Disc E07 PUMP Electrical system
DXACKB P2F EPC Sol S/C E07 PUMP Electrical system
DXADKA P2R EPC Sol Disc E07 PUMP Electrical system
DXADKB P2R EPC Sol S/C E07 PUMP Electrical system
DY2CKB Washer Drive S/C — PUMP Electrical system
DY20MA Low Wiper Working Abnormality — PUMP Electrical system
DY2FMA Upper Wiper Working Abnormality — PUMP Electrical system
F@BBZL VHMS Troubleshooting
High Blowby Pressure — VHMS by failure code,
[n3o38] [n3o38]
Part 7
F@BYNR VHMS SEN02102-00
Very High LBF CYL Exhaust Temp — VHMS
[n3o62] [n3o62]
f@BYNR VHMS
Very High LBR CYL Exhaust Temp — VHMS
[n3o72] [n3o72]
F@BYNS VHMS
High LBF CYL Exhaust Temp — VHMS
[n3o61] [n3o61]
f@BYNS VHMS
High LBR CYL Exhaust Temp — VHMS
[n3o71] [n3o71]
F@BZNR VHMS
Very High RBF CYL Exhaust Temp — VHMS
[n3o82] [n3o82]
f@BZNR VHMS
Very High RBR CYL Exhaust Temp — VHMS
[n3o92] [n3o92]
F@BZNS VHMS
High RBF CYL Exhaust Temp — VHMS
[n3o81] [n3o81]
f@BZNS VHMS
High RBR CYL Exhaust Temp — VHMS
[n3o91] [n3o91]
LA10ZL RAD Fan Pump Relief Press Abnormality — PUMP Mechanical system
LA20ZL O/C Fan Pump Relief Press Abnormality — PUMP Mechanical system
a This table lists the failed sections in the order of the failure code.
a Those failure codes to which the corresponding number is not indicated in the action code space are not
displayed on the ordinary screen if a failure is found. They are just recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
a The category of record is used for indicating to which of the electrical and mechanical system of the ser-
vice menu's abnormality record a given failure is classified. VHMS failure codes, which are available
only in VHMS specifications, are stored only in VHMS controller; therefore, they are not recorded in the
abnormality record. In addition, four-digit codes in the (bracket) of VHMS indicate the failure codes (dis-
played two digits each) displayed by the 7-segment LED of VHMS controller.
a E at the head of the action code indicates the following state:
q With E: The failure still remains without being resolved.
q Without E: The failure is already resolved.
8 PC2000-8
Before carrying out troubleshooting of electrical system 1

Connection table of circuit breakers
a This connection table shows the devices to which each power supply of the circuit breaker supplies
power (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power irrespective of the starting switch
position).
a When carrying out troubleshooting related to a failure code, you should first check the circuit breaker to
see if the power is supplied normally.
q Circuit breaker (B) (Large capacity breaker)

Circuit breaker (B)
Type of power Terminal numbers Destination of
supply are shown in power
brackets ( ).
30A
(B21A-B21B)
30A
(B22A-B22B)
20A
(B23A-B23B)
(1)
Fuse
60A
(6) – (10)
(B11-B12)
Switch power 20A
supply (B24A-B24B)
(battery relay M 20A
terminal) (B25A-B25B)
20A
(B26A-B26B)
Fuse
(1) – (5)
(2) (11) – (13)
60A
(B13-B14) Connector B05
(Optional power
supply)
20A
(B27A-B27B)
30A
Constant power (B28A-B28B)
(3)
supply 30A
60A
(battery relay B (B29A-B29B)
(B17-B18)
terminal) 30A
(B30A-B30B)
Fuse
(16) – (20)
(4)
Intake air heater
Switch power 105A
relay (1)
supply (B6A-B6B)
(battery relay M (5)
terminal) Intake air heater
105A
relay (2)
(B5A-B5B)
* Figure in the ( ) shows a circuit breaker num-

ber in the circuit diagram
PC2000-8 9
q Circuit breaker (A)

Circuit breaker (A)
Type of power Terminal num- Destination of
supply bers are shown in power
brackets ( ).
(1)
20A Pump controller 2
(B25A-B25B)
(2)
20A Pump controller 1
(B24A-B24B)
PPC lock sole-
Circuit breaker (3) noid valve
(2) for switch 20A Working lamp
power supply (B23A-B23B) power supply
60A (R08 relay)
Right working
(4)
lamp power sup-
30A
ply
(B22A-B22B)
(R10 relay)
(5) Left working lamp
30A power supply
(B21A-B21B) (R11 relay)
(6)
Engine right con-
30A
troller
(B30A-B30B)
(7)
Engine left con-
30A
troller
Constant power (B29A-B29B)
supply circuit Starting switch
breaker (3) (8) Machine monitor
60A 30A
(B28A-B28B) Pump controller 1
Pump controller 2
(9) VHMS controller
20A ORBCOM con-
(B27A-B27B) troller
Switch power
(10)
supply circuit
20A VHMS controller
breaker (1)
(B26A-B26B)
60A
* Figure in the ( ) shows a circuit breaker num-

ber in the circuit diagram
10 PC2000-8
Location of circuit breakers 2. Circuit breaker (A)

1. Circuit breaker (B) (Large capacity breaker) (Arranged to the downstream of circuit breaker
Located in the box (2) on the side of battery (B))
room (1). Located in the distribution board inside the cab
base.
PC2000-8 11
Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power irrespective of the starting switch position).
a When carrying out troubleshooting related to a failure code, you should first check the fuse box to see if
the power is supplied normally.
Type of power supply Fuse No. Fuse capacity Destination of power

1 10A Emergency swing holding brake solenoid valve
Machine push-up switch
2 10A
Switch power supply circuit Boom damping solenoid valve
breaker (B) PPC oil pressure lock solenoid valve
3 10A
(2) (60A) Starter cut relay
(B13-B14)
4 10A Cigarette lighter
Horn
5 10A
Flash light
6 10A Bottom dump solenoid valve
7 10A Rotary lamp
Switch power supply circuit
breaker (B) 8 10A Auxiliary lamp
(1) (60A) 9 10A Radio
(B11-B12) Wiper
10 30A
Windshield washer
Switch power supply circuit 11 20A Air conditioner unit (upper)
breaker (B) 12 20A Air conditioner unit (lower)
(2) (60A)
(B13-B14) 13 20A 12 V power supply
14 5A Left bank engine controller (ACC) circuit
Fuse in the circuit diagram
15 5A Right bank engine controller (ACC) circuit
16 10A Radio backup, room lamp
17 10A Network bus power supply
Engine controller
Constant power supply circuit
breaker (B) 18 20A Pump controller
(3) (60A) Room lamp (cab base)
(B17-B18) Room lamp (cab)
19 20A
Emergency stop circuit
20 10A Step light
* The bracket ( ) under the breaker shows a breaker terminal number
12 PC2000-8
Location of fuse
Located in the distribution board inside the cab
base.
PC2000-8 13
SEN02011-00

© 2006 KOMATSU
All Rights Reserved
14
SEN02012-00
PC2000-8

PC2000-8 20001 and up
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting........................................................................................... 2
Sequence of events in troubleshooting ................................................................................................ 3
Checks before troubleshooting ............................................................................................................ 4
Classification and procedures of troubleshooting ................................................................................ 5
Connection table for connector pin numbers ....................................................................................... 9
T-adapter box and T-adapter table ..................................................................................................... 42
PC2000-8 1
General information on troubleshooting 1

Points to remember when troubleshooting 1
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Are abnormal symptoms detected in the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part
exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure
occurred. Then, remove the root cause.
2 PC2000-8
Sequence of events in troubleshooting 1
PC2000-8 3
Checks before troubleshooting 1

Item Criterion Remedy
1. Check of level and type of fuel — Add fuel
2. Check of fuel for foreign matter — Clean and drain
3. Check of fuel filter — Replace
4. Check of hydraulic oil level — Add oil
Lubricating 5. Check of hydraulic oil strainer — Clean and drain

oil, Coolant 6. Check of swing machinery oil level — Add oil
7. Check of level and type of engine oil (in oil pan) — Add oil
8. Check of coolant level — Add coolant
9. Check of dust indicator for clogging — Clean or replace
10. Check of hydraulic oil filter — Replace
1. Check of battery terminals and wiring for looseness
— Retighten or replace
and corrosion
Electrical 2. Check of alternator terminals and wiring for looseness
equipment and corrosion
3. Check of starting motor terminals and wiring for loose-
ness and corrosion
Hydraulic,
1. Check for abnormal noise and smell — Repair
Mechanical 2. Check of oil leakage — Repair
equipment
3. Bleeding air — Bleed air
1. Check of battery voltage (with engine stopped) 20 – 30 V Replace
2. Check of electrolyte level — Add or replace
3. Check of wires for discoloration, burn, and removal of
— Replace
cover
4. Check for released wire clamp and drooping wire — Repair
Electric, 5. Check of wires for wetness (Check connectors and Disconnect the
electrical —
terminals for wetness, in particular) connectors and dry
equipment
6. Check of fuse for disconnection and corrosion — Replace
7. Check of alternator voltage (while engine speed is at After operating for
middle or higher) several minutes: Replace
27.5 – 29.5 V
8. Check of battery relay for operating sound (When
— Replace
starting switch is turned ON or OFF)
4 PC2000-8
Classification and procedures of troubleshooting 1

Classification of troubleshooting code
Troubleshooting
Contents
code
Code display Troubleshooting by [electrical system] or [mechanical system] failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Troubleshooting procedures
If a problem occurs on the machine, or if it is felt that there is a problem, carry out troubleshooting as follows.
1. When machine monitor displays user code

If a user code is displayed on the machine monitor at the same time as the problem occurs, check the
content of the display, then go to the applicable troubleshooting chart for the failure code.
2. When machine monitor does not display failure code, but failure history is recorded
If a problem occurs but the user code display cannot be checked on the machine monitor, use the failure
history display function in the machine monitor service mode to check for a failure code.
If a failure code is recorded, there is a high probability that this is the cause, so go to the applicable trou-
bleshooting chart.
3. When a user code is not displayed and failure history is not recorded either
If a problem occurs but the user code display cannot be checked on the machine monitor, and also the
problem is not recorded by the failure history display function in the machine monitor service mode, the
problem of the electrical, hydraulic or mechanical system that cannot be detected by a controller may
have occurred.
In this case, check the symptom of the trouble and go to the applicable troubleshooting chart.
PC2000-8 5
Failure-looking Phenomenon and Troubleshooting No.
Troubleshooting
No. Failure-looking phenomenon Code
E-mode H-mode S-mode
display
Action to be taken concerning user code and failure code
1 Display user code in machine monitor Accord-
2 Display failure code in electrical system after checking failure history ing to dis-
Display failure code in mechanical system after checking failure his- played
3 code
tory
Engine-related failure
Engine does not start up easily. (It always takes some time to start up
4 S-1
the engine)
5 Engine does not rotate E-3 S-2 1)
6 Engine rotates, but there is no exhaust gas S-2 2)
Engine does not start
There is exhaust gas, but engine does not
7 S-2 3)
start
8 Engine pickup is poor. (Engine does not follow acceleration) S-3
9 Engine stops while in operation S-4
10 Engine rotation is irregular. (There is hunting) S-5
11 Engine is short of output, or lacks power S-6
12 Color of exhaust gas is too dark. (Incomplete combustion) S-7
13 Excessive engine oil consumption, or color of exhaust gas is blue S-8
14 Premature engine oil contamination S-9
15 Excessive fuel consumption S-10
16 Engine coolant is mixed with engine oil, spurts out or decreases S-11
17 Engine oil amount increases. (Coolant or fuel gets in) S-13
18 Abnormal noises are heard S-15
19 Excessive vibrations are caused S-16
20 Auto-decelerator does not work E-4
21 Engine auto warming-up device does not work E-5
22 Engine preheater does not work E-6
Failure related to work equipment, swing and travel
23 Speed or power of all work equipment, travel, and swing is low H-1 S-6
24 Engine speed lowers remarkably or engine stalls H-2 S-4
25 All work equipment, travel, and swing systems do not work E-7 H-3
26 Abnormal sound is heard from around pump H-4
6 PC2000-8
Troubleshooting
E mode H mode S mode
display
Work equipment-related failure
27 Speed or power of boom is low H-5
28 Speed or power of arm is low H-6
29 Speed or power of bucket is low H-7
30 Boom does not move H-8
31 Arm does not move H-9
32 Bucket does not move H-10
33 Hydraulic drift of work equipment is large H-11
34 Time lag of work equipment is large H-12
35 Machine push-up circuit does not work E-8 H-14
36 Heavy lift function does not work or is not reset H-13
37 Boom shockless function cannot be turned ON or OFF E-9 H-15
Travel-related failure
38 Machine deviates in one direction H-16
39 Machine deviates largely at start H-17
40 Machine deviates largely during compound operation H-18
41 Travel speed or power is low H-19
42 Machine does not travel (only one track) H-20
Swing-related failure
43 Machine does not swing H-21
44 Swing speed or acceleration is low H-22
Swing speed or power is low in compound operation of travel and
45 H-23
bucket
46 Upper structure overruns largely H-24
47 Large shocks are made when upper structure stops swinging H-25
Large abnormal sounds are made when upper structure stops swing-
48 H-26
ing
49 Hydraulic drift of swing is large H-27
Fan rotation is abnormal (large noise or vibration of fans, or fan over-
50 H-28
heating)
Machine monitor-related failure (Operator's Menu: ordinary display)
51 When starting switch turned ON, machine monitor displays nothing E-1
When starting switch turned ON (before starting engine), basic check
52 E-2
item lights up
53 Machine monitor does not display some items E-10
Contents of display by machine monitor are different from applicable
54 E-11
machine
PC2000-8 7
Troubleshooting
E mode H mode S mode
display
55 While engine is running, fuel level monitor lamp lights up red E-12
56 Hydraulic oil temperature gauge does not display correctly E-13
57 Fuel gauge does not display correctly E-14
58 Swing lock monitor does not display correctly E-15
59 When operating monitor switch, no display appears E-16
60 Windshield wiper does not work E-17
Monitor panel-related failure (Service Menu: Special Function Display)
61 In monitoring function, “Travel” cannot be displayed correctly E-18
Other failure
62 Travel alarm does not sound E-19
63 Any of room lamp, head lamp, working lamp does not light up E-20
64 Air conditioner does not work E-21
65 Step light does not light up or light off E-22
Radiator fan rotation is abnormal (Fan noise or vibration is excessively
66 H-28
large or overheats)
8 PC2000-8
Connection table for connector pin numbers (Rev. 2006.11)

a The terms male and female refer to the pins, while the terms male housing and female housing refer to
the mating portion of the housing.
PC2000-8 9
10 PC2000-8
PC2000-8 11
12 PC2000-8
PC2000-8 13
14 PC2000-8
PC2000-8 15
16 PC2000-8
PC2000-8 17
18 PC2000-8
PC2000-8 19
20 PC2000-8
PC2000-8 21
22 PC2000-8
PC2000-8 23
24 PC2000-8
PC2000-8 25
26 PC2000-8
PC2000-8 27
28 PC2000-8
PC2000-8 29
30 PC2000-8
PC2000-8 31
32 PC2000-8
PC2000-8 33
34 PC2000-8
PC2000-8 35
36 PC2000-8
PC2000-8 37
38 PC2000-8
PC2000-8 39
40 PC2000-8
PC2000-8 41
T-adapter box and T-adapter table (Rev. 2006.11)

a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37
799-601-3200 T-box (for MS) 37
799-601-3380 • Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4210 Adapter for DRC 50 DRC50 q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
42 PC2000-8
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
PC2000-8 43
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
799-601-9320 T-box (for DT/HD) 12 q q q

799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 3 A3 q q
Adapter for engine (CRI-T3) PFUEL
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 q
799-601-4280 Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9370 Adapter for controller (HST) 26 HST26A q
“*” Shows not T-adapter but socket.
44 PC2000-8
SEN02012-00

© 2006 KOMATSU
All Rights Reserved
46
SEN02096-00
PC2000-8

PC2000-8 20001 and up
Troubleshooting by failure code, Part 1
Troubleshooting by failure code, Part 1 .......................................................................................................... 3
Failure code [0410KA] Fuel LV. Sensor Failure ................................................................................... 3
Failure code [0410KB] Fuel LV. Sensor Failure ................................................................................... 4
Failure code [6014NX] Hydraulic Oil Filter Clogging
(or change of VHMS-LED display from n5 to 51)....................................................................... 5
Failure code [8800ZG] Auto grease abnormally .................................................................................. 6
Failure code [7@HAZL] VR1/P1F Relief Press Abnormality................................................................ 7
Failure code [7@HBZL] VL1/P1R Relief Press Abnormality................................................................ 8
Failure code [7@HCZL] VR2/P2F Relief Press Abnormality ............................................................... 9
Failure code [7@HDZL] VL2/P2R Relief Press Abnormality.............................................................. 10
Failure code [AA10NX] Aircleaner Clogging ...................................................................................... 12
Failure code [AB00KE] Charge Voltage Low ..................................................................................... 14
Failure code [aB00KE] Low Upper ALR Charge Voltage
(or change of VHMS-LED display from n9 to 11) ..................................................................... 16
Failure code [B@BAZG] Eng. Oil Press. Low .................................................................................... 18
Failure code [B@BAZK] Eng. Oil Level Low ...................................................................................... 20
PC2000-8 1
Failure code [B@BCNS] Eng. Water Overheat.................................................................................. 22

Failure code [B@BCZK] Eng. Water Lvl Low ..................................................................................... 24
Failure code [B@CBNS] PTO Oil Overheat (or change of VHMS-LED display from n5 to 61).......... 26
Failure code [B@HANS] Hydr. Oil Overheat ...................................................................................... 28
Failure code [B@HAZK] Low Hydraulic Oil Level (or change of VHMS-LED display from n5 to 52) . 30
Failure code [CA111] ECM Critical Internal Failure ............................................................................ 32
Failure code [CB111] ECM Critical Internal Failure ............................................................................ 34
Failure code [CA115] Eng. Ne and Bkup Speed Sens Error .............................................................. 36
Failure code [CB115] Eng. Ne and Bkup Speed Sens Error .............................................................. 37
Failure code [CA122] Chg Air Press Sensor High Error..................................................................... 38
Failure code [CA123] Chg Air Press Sensor Low Error ..................................................................... 40
Failure code [CA131] Throttle Sensor High Error............................................................................... 42
Failure code [CA132] Throttle Sensor Low Error ............................................................................... 44
Failure code [CA135] Eng Oil Press Sensor High Error..................................................................... 46
Failure code [CA141] Eng Oil Press Sensor Low Error...................................................................... 48
Failure code [CA144] Coolant Temp Sens High Error........................................................................ 50
Failure code [CA145] Coolant Temp Sens Low Error......................................................................... 52
Failure code [CA153] Chg Air Temp Sensor High Error ..................................................................... 54
Failure code [CA154] Chg Air Temp Sensor Low Error...................................................................... 56
Failure code [CA187] Sens Supply 2 Volt Low Error.......................................................................... 58
Failure code [CB187] Sens Supply 2 Volt Low Error.......................................................................... 58
Failure code [CA212] Eng Oil Temp Sensor High Error ..................................................................... 60
Failure code [CA213] Eng Oil Temp Sensor Low Error ...................................................................... 62
2 PC2000-8
Troubleshooting by failure code, Part 1 1

Failure code [0410KA] Fuel LV. Sensor Failure 1
User code Failure code Fuel LV. Sensor Failure
Trouble
— 0410KA (Machine monitor system)
Contents of
• No sensor current
trouble
Action of
• None in particular.
controller
Problem that
• While fuel is added, fuel level gauge does not rise from red range (E).
appears on
• While fuel level is low, fuel level gauge does not lower from green range (F).
machine
Related
information
Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective fuel level
sensor (internal dis- P21A (male) Fuel level Resistance
1 +1.0
connection or short cir- FULL (Upper limit) 10 –3.0 z
cuit) Between (1) and
chassis ground +10
EMPTY (Lower limit) 85 0 z
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without
harness (Disconnec- turning starting switch ON.
Possible 2
tion or defective con- Wiring harness between CM01 (female) (9) –
causes and tact in connector) Resistance Max. 1 z
P21A (female) (1)
standard value
in normal state a Prepare with starting switch OFF, then turn starting switch ON and carry
Hot short in wiring har-
out troubleshooting.
3 ness (Contact with 24
Wiring harness between CM01 (female) (9) –
V circuit) Voltage Max. 1 V
P21A (female) (1)
CM01 (female) Fuel level Resistance
Defective machine
4 +1.0
monitor FULL (Upper limit) 10 –3.0 z
Between (9) and
chassis ground +10
Circuit diagram related to fuel level sensor
PC2000-8 3
Failure code [0410KB] Fuel LV. Sensor Failure 1

User code Failure code Fuel LV. Sensor Failure
Trouble
— 0410KB (Machine monitor system)
Contents of
• Sensor current flows.
trouble
Action of
controller
Problem that
appears on • Fuel level monitor lights up while engine is running
machine
Related
information

Low fuel level (when
1 a Add fuel.
the system is normal)
sensor (internal dis- P21A (male) Fuel level Resistance
2 +1.0
connection or short cir- FULL (Upper limit) 10 –3.0 z
cuit) Between (1) and
chassis ground +10
Possible EMPTY (Lower limit) 85 0 z
causes and
standard value Ground fault in wiring
in normal state turning starting switch ON.
3 harness (Contact with
Between harness CM01 (female) (9) – P21A
GND circuit) Resistance Min. 1 Mz
(female) (1) and the grounding
CM01 (female) Fuel level Resistance
Defective machine
4 +1.0
monitor FULL (Upper limit) 10 –3.0 z
Between (9) and
chassis ground +10
4 PC2000-8
Failure code [6014NX] Hydraulic Oil Filter Clogging (or change of

VHMS-LED display from n5 to 51) 1
User code Failure code Hydraulic Oil Filter Clogging
Trouble
— 6014NX (VHMS controller system)
Contents of • While engine was running, signal circuit of hydraulic oil filter clogging sensor was opened (discon-
trouble nected from GND).
Action of
controller
Problem that
appears on • None in particular.
machine
Related • Failure codes of VHMS system are not recorded on the trouble data of the machine monitor.
information • VHMS controller 7-segment LED display: n5 o 51 (codes are displayed by 2 digits)

Clogging of hydraulic
1 oil filter (when the sys- Check the hydraulic oil filter, and replace it if clogged.
tem is normal)
Defective hydraulic oil turning starting switch ON.
filter clogging switch
2 P40 (male) Hydraulic oil filter Resistance
(Internal disconnec-
Value in normal state Max. 1 z
tion or short circuit) Between (1) and (2)
Value when clogged Min. 1 Mz
Possible Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without
causes and harness (Disconnec- turning starting switch ON.
3
standard value tion or defective con- Wiring harness between CV02B (female) (1) –
in normal state tact in connector) Resistance Max. 1 z
P40 (female) (1)
Ground fault in wiring
GND circuit) Between wiring harness of CV02B (female) (1) –
Resistance Min. 1 Mz
P40 (female) (1) and the grounding
a Prepare with starting switch OFF, start engine and then carry out trou-
bleshooting.
Defective VHMS
5 CV02B Hydraulic oil filter Voltage
controller
Between (1) and Value in normal state Max. 1V
chassis ground Value when clogged 20 – 30 V
Circuit diagram related to hydraulic oil clogging sensor
PC2000-8 5
Failure code [8800ZG] Auto grease abnormally 1

User code Failure code Auto grease abnormally
Trouble
— 8800ZG (Pump controller 2 system)
• Abnormality occurred to the grease pump pressure sensor circuit.
Contents of
• When the grease pressure fails to reach set standard level during automatic or forcible greasing.
trouble
Default value: Max. 19.6 MPa {Max. 200 kg/cm3}/min.
Action of
• None in particular (Provides the error display alone).
controller
Problem that
• Grease level is low.
appears on
• The automatic lubrication cannot work.
machine
Related • Input from the automatic greasing pressure sensor can be checked with monitoring function.
information (Monitoring code: 13900, automatic greasing pressure)

Grease level is low
1 (when the system is Check the grease level, and add it if low.
normal)
Possible Defective grease pump If failure code [DHPSKX] is displayed, carry out the troubleshooting first as
causes and pressure sensor (inter- stated.
2
standard value nal disconnection or if failure code [dA25KP] is displayed, carry out the troubleshooting first as
in normal state short circuit) stated.
a Prepare with starting switch OFF (disconnect P48), then turn the switch
Defective pump ON and carry out troubleshooting.
3
controller 2 Between CP04
Voltage Max. 0.8 V
(3) – (21)
Circuit diagram related to grease pump pressure sensor
6 PC2000-8
Failure code [7@HAZL] VR1/P1F Relief Press Abnormality 1

User code Failure code VR1/P1F Relief Press Abnormality
Trouble
— 7@HAZL (pump controller 1 system)
Contents of • Signal circuit of VR1/P1F system pump pressure sensor detected 37.3 MPa or higher {380 kg/cm2}
trouble or higher).
Action of
controller
Problem that
appears on • If machine is operated as it is, hydraulic components may be damaged.
machine
• Pump pressure of VR1/P1F system can be checked with the machine monitor.
Related
Monitoring code: 01124, P1F pump pressure
information
PM clinic (7/12), (8/12) and (10/12)

Abnormal high-pres-
sure of VR1/P1F sys-
1 tem pump pressure Check VR1/P1F system pump relief pressure. Correct, if any.
(when the system is
Possible normal)
causes and If failure code [OHPEKX] is displayed, carry out troubleshooting for it first.
Defective VR1/P1F
standard value 2 system pump pres- If failure code [DA25KP] is displayed, carry out the troubleshooting as
in normal state
sure sensor stated.
Defective pump bleshooting.
3
controller 1 CP01 Voltage
Between (9) and (21) Max. 0.8 V
Circuit diagram related to VR1/P1F system pump pressure sensor
PC2000-8 7
Failure code [7@HBZL] VL1/P1R Relief Press Abnormality 1

User code Failure code VL1/P1R Relief Press Abnormality
Trouble
— 7@HBZL (Pump controller 1 system)
Contents of • Signal circuit of VL1/P1R system pump pressure sensor detected 37.3 MPa or higher {380 kg/cm2}
trouble or higher).
Action of
controller
Problem that
machine
• Pump pressure of VL1/P1R system can be checked with the machine monitor.
Related
Monitoring screen: monitoring code: 01125, P1R pump pressure
information
PM clinic (7/12), (8/12) and (10/12)

Abnormal high-pres-
sure of VL1/P1R sys-
1 tem pump pressure Check VL1/P1R system pump relief pressure. Correct, if any.
(when the system is
Possible normal)
causes and If failure code [DHPFKX] is displayed, carry out the troubleshooting as
Defective VL1/P1R
standard value stated.
2 system pump pres-
in normal state If failure code [DA25KP] is displayed, carry out the troubleshooting as
sure sensor system
stated.
3
Circuit diagram related to VL1/P1R system pump pressure sensor
8 PC2000-8
Failure code [7@HCZL] VR2/P2F Relief Press Abnormality 1

User code Failure code VR2/P2F Relief Press Abnormality
Trouble
— 7@HCZL (Pump controller 1 system)
Contents of • Signal circuit of VR2/P2F system pump pressure sensor detected 37.3 MPa or higher ({380 kg/cm2}
trouble or higher).
Action of
controller
Problem that
machine
• Pump pressure of VR2/P2F system can be checked with the machine monitor.
Related
Monitoring screen: monitoring code: 01126, P2F pump pressure
information
PM clinic (7/12), (9/12) and (11/12)

Abnormal high-pres-
sure VR2/P2F system
1 Check VR2/P2F system pump relief pressure. Correct, if any.
pump pressure (when
Possible If failure code [DHPGKX] is displayed, carry out the troubleshooting as
causes and Defective VR2/P2F stated.
standard value 2 system pump pres-
sure sensor system If failure code [DA25KP] is displayed, carry out the troubleshooting as
in normal state
stated.
3
Circuit diagram related to VR2/P2F system pump pressure sensor
PC2000-8 9
Failure code [7@HDZL] VL2/P2R Relief Press Abnormality 1

User code Failure code VL2/P2R Relief Press Abnormality
Trouble
— 7@HDZL (Pump controller 1 system)
Contents of • Signal circuit of VL2/P2R system pump pressure sensor detected 37.3 MPa or higher {380 kg/cm2}
trouble or higher).
Action of
controller
Problem that
machine
• Pump pressure of VL2/P2R system can be checked with the machine monitor.
Related
Monitoring screen: monitoring code: 01127, P2R pump pressure
information
PM clinic (7/12), (9/12) and (11/12)

Abnormal high-pres-
sure of VL2/P2R sys-
1 tem pump pressure Check VL2/P2R system pump relief pressure. Correct, if any.
(when the system is
Possible normal)
causes and If failure code [DHPHKX] is displayed, carry out the troubleshooting as
Defective VL2/P2R
standard value stated.
2 system pump pres-
in normal state If failure code [DA25KP] is displayed, carry out the troubleshooting as
sure sensor
stated.
3
10 PC2000-8
Circuit diagram related to VL2/P2R system pump pressure sensor
PC2000-8 11
Failure code [AA10NX] Aircleaner Clogging 1

User code Failure code Aircleaner Clogging
Trouble
— AA10NX (Machine monitor system)
Contents of • While engine was running, signal circuit of air cleaner clogging sensor was opened (disconnected
trouble from GND).
Action of
controller
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• If an air cleaner clogging monitor on the machine monitor lights up in red while the engine is run-
Related ning, this failure code will be recorded.
information • Input from the air cleaner clogging switch (ON/OFF) can be checked with monitoring function.
(Code: 04501, Monitor Input 2)

Clogging of air cleaner
1 (when the system is Check the air cleaner for clogging and then clean or replace it if clogged.
normal)
a Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting in each case.
Defective air cleaner
P23A (male) and
2 clogging sensor (inter- Air cleaner Resistance
P23B (male)
nal disconnection)
Between (1) and (2)
Possible turning starting switch ON.
causes and
standard value Resistance Max. 1 z
in normal state Disconnection in wiring P23A (female) (1)
harness (Disconnec- Wiring harness between CM02 (female) (4) –
3 Resistance Max. 1 z
tion or defective con- P23B (female) (1)
tact in connector) Wiring harness between P23A (female) (2) – JE6
Resistance Max. 1 z
and chassis ground
Wiring harness between P23B (female) (2) – JE6
Resistance Max. 1 z
and chassis ground
Defective machine CM02 Air cleaner Voltage
4
monitor
Between (4) and chas- Value in normal state Max. 1 V
sis ground Value when clogged 20 – 30 V
12 PC2000-8
Circuit diagram related to aircleaner clogging sensor
PC2000-8 13
Failure code [AB00KE] Charge Voltage Low 1

User code Failure code
Trouble Charge Voltage Low (Mechanical system)
— AB00KE
Contents of
• Signal voltage from alternator is below 20 V while the engine is running.
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, battery may not be charged.
machine
• If a charge level monitor on the machine monitor lights up in red while the engine is running, this fail-
Related ure code will be recorded.
information • Input from alternator (voltage, ON or OFF) can be checked with monitoring function.
(Code 04300: Charge voltage, 04501: Monitor input 2)

a Prepare with starting switch OFF, then start engine and carry out trou-
bleshooting.
Defective alternator Alternator Engine Voltage
1 (Low power genera-
tion) Between R terminal –
Above low idle 27.5 – 29.5 V
chassis ground
If the voltage is abnormal, check the belt tension too.
harness turning starting switch ON.
2 (Disconnection in wiring
Possible or defective contact in Wiring harness between CM01 (female) (11) – Resistance Max. 1 z
causes and connector) JB113 – Alternator R terminal
standard value a Prepare with starting switch OFF, then carry out troubleshooting without
harness Between wiring harness between CM01 (female)
3 (11), JB113, and alternator terminal R, or
(Short circuit with GND
circuit) between P02 (female) (11), or between P02 Resistance Min. 1 Mz
(female) (11), battery relay terminal BR and
grounding
bleshooting.
Defective machine
4 CM01 Engine Voltage
monitor
Between (11) –
Above low idle 27.5 – 29.5 V
chassis ground
14 PC2000-8
Circuit diagram related to engine preheating, starting and charging circuits
PC2000-8 15
Failure code [aB00KE] Low Upper ALR Charge Voltage (or change of
User code Failure code Low Upper ALR Charge Voltage
Trouble
— aB00KE (VHMS controller system)
Contents of
• While engine is running, power generation signal from the upper alternator is not input.
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, battery may not be charged.
machine

bleshooting.
Defective alternator
1 Alternator Engine speed Voltage
(low power generation)
Between terminal R –
Medium or higher 27.5 – 29.5 V
chassis ground
2 Disconnection in wiring
Possible tion or defective con- Wiring harness between CV02A (female) (4) and
causes and Resistance Max. 1 z
tact in connector) Alternator R terminal
standard value
in normal state a Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring turning starting switch ON.
GND circuit) Between CV02A (female) (4) and Alternator R
Resistance Max. 1 Mz
terminal
bleshooting.
Defective VHMS
4 CV02A Engine speed Voltage
controller
Between (4) and chas-
Medium or higher 27.5 – 29.5 V
sis ground
16 PC2000-8
Circuit diagram related to engine preheating, starting and charging circuits
PC2000-8 17
Failure code [B@BAZG] Eng. Oil Press. Low 1

User code Failure code Eng. Oil Press. Low
Trouble
— B@BAZG (Engine controller system)
Contents of • While engine was running, signal circuit of engine oil pressure switch detected low engine oil pres-
trouble sure (opening of sensor contact).
Action of
• Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
controller
Problem that
appears on If machine is operated as it is, engine may be damaged.
machine
• Input (Voltage) from oil pressure sensor can be checked with monitoring function (Code: 37200).
Related • Signals of engine oil pressure switch are input to engine controller and then transmitted to machine
information monitor through communication system.
• Method of reproducing failure code: Start engine.

Defective sensor If code [CA187] or [CA227] is indicated, carry out troubleshooting for it
1
power supply system first.
engine and carry out troubleshooting.
Defective oil pressure POIL Voltage
2 sensor (Internal trou- Between (1) – (2) Power supply 4.75 – 5.25 V
ble)
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for another
cause of trouble, and then judge.
Disconnection in wiring Wiring harness between ENG (L) (female) (37) –
Possible Resistance Max. 1 z
harness (Disconnec- POIL (female) (1)
causes and
3 tion in wiring or defec-
standard value Wiring harness between ENG (L) (female) (47) –
tive contact in Resistance Max. 1 z
in normal state POIL (female) (2)
connector)
Wiring harness between ENG (L) (female) (13) –
Resistance Max. 1 z
POIL (female) (3)
4 harness (Short circuit Resistance Min. 1 Mz
POIL (female) (1) and chassis ground
with GND circuit)
POIL (female) (3) and chassis ground
Defective engine engine and carry out troubleshooting.
5
controller ENG (L) Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
18 PC2000-8
Circuit diagram related to engine oil pressure sensor
PC2000-8 19
Failure code [B@BAZK] Eng. Oil Level Low 1

User code Failure code Eng. Oil Level Low
Trouble
— B@BAZK (Machine monitor system)
Contents of • The signal circuit of the engine oil level sensor is opened (disconnected from grounding) while the
trouble engine is stopped.
Action of
controller
Problem that
machine
• If the engine oil level monitor on the machine monitor lights up in red while the engine is running,
Related this failure code is recorded.
information • Input from the engine oil level sensor (ON or OFF) can be checked in the monitoring function.
(Code No. 04501: Monitor input 2)

Lowering of engine oil
level a Check the engine oil level and add new oil.
1
(when system is nor- (If this phenomenon frequently occurs, investigate the cause.)
mal)
Defective engine oil turning starting switch ON.
level sensor OLLV (male) Engine oil level Resistance
2
Possible tion) Normal level Max. 1 z
Between (1) – (2)
causes and Below normal level Min. 1 Mz
standard value Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without
in normal state harness turning starting switch ON.
3 (Disconnection in wiring
or defective contact in Wiring harness between CM02 (female) (2) – Resistance Max. 1 z
connector) OLLV (female) (1)
a Prepare with starting switch OFF, then turn starting switch ON and carry
Defective machine CM02 Engine oil level Voltage
4
monitor
Between (2) – Normal level Max. 1 V
chassis ground Below normal level 20 – 30 V
20 PC2000-8
Circuit diagram related to engine oil level sensor
PC2000-8 21
Failure code [B@BCNS] Eng. Water Overheat 1

User code Failure code Eng. Water Overheat
Trouble
— B@BCNS (Engine controller system)
Contents of
• The signal circuit of the engine coolant temperature sensor detected temperature above 105°C
trouble
Action of
• Fixes coolant temperature (90°C) and continues operation.
controller
Problem that
machine
• Input from the engine coolant temperature sensor (temperature) can be checked with monitoring func-
Related tion (Code: 04107)
information • Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor.

Defective coolant tem- turning starting switch ON.
1 perature sensor (Inter- Coolant
TWTR (male) Resistance
nal trouble) temperature
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Disconnection in wiring turning starting switch ON.
harness (Disconnec-
2 tion in wiring or defec- Resistance Max. 1 z
Possible TWTR (female) (A)
tive contact in
causes and connector) Wiring harness between ENG (L) (female) (38) –
TWTR (female) (B)
in normal state
Ground fault in wiring a Prepare with starting switch OFF, then carry out troubleshooting without
3
(Short circuit with GND Between wiring harness of ENG (L) (female) (15)
circuit) Resistance Min. 1 Mz
– TWTR (female) (A) and chassis ground
Defective engine Engine coolant
4 ENG (L) (female) Resistance
controller temperature
Between (15) – (38)
10 – 100°C 0.6 – 20 kz
chassis ground
22 PC2000-8
Circuit diagram related to coolant temperature sensor
PC2000-8 23
Failure code [B@BCZK] Eng. Water Lvl Low 1

User code Failure code Eng. Water Lvl Low
Trouble
— B@BCZK (Machine monitor system)
Contents of • While engine was running, signal circuit of radiator coolant level sensor was opened (disconnected
trouble with GND).
Action of
controller
Problem that
appears on • If machine is operated as it is, engine may overheat.
machine
• If the radiator coolant level monitor on the machine monitor lights up in red while the engine is
Related stopped (the starting switch is at the ON position), this failure code is recorded.
information • Input from the radiator coolant level sensor (ON/OFF) can be checked with monitoring function.
(Code 04500: Monitor Input 1)

Sub-tank coolant level
Check the radiator sub-tank coolant level. If it is low, add coolant.
1 low (While system is
(If it is reduced frequently, find out the cause.)
normal)
Defective radiator cool- turning starting switch ON.
ant level sensor 1 P24A (male) Sub-tank coolant level Resistance
2
tion) Within normal level Max. 1 z
Between (1) – (2)
Possible Below LOW level Min. 1 Mz
causes and a Prepare with starting switch OFF, then carry out troubleshooting without
standard value Disconnection in wiring turning starting switch ON.
in normal state harness
3 (Disconnection in wiring Resistance Max. 1 z
P24 (female) (1)
or defective contact in
connector) Wiring harness between P24 (female) (2) – chas-
Resistance Max. 1 z
sis ground
Defective machine CM02 Sub-tank coolant level Voltage
4
monitor
Between (3) – Within normal level Max. 1 V
chassis ground Below LOW level 20 – 30 V
24 PC2000-8
Circuit diagram related to radiator coolant level switch
PC2000-8 25
Failure code [B@CBNS] PTO Oil Overheat (or change of VHMS-LED

display from n5 to 61) 1
User code Failure code PTO Oil Overheat
Trouble
— B@CBNS (VHMS controller system)
Contents of • Signal circuit of PTO oil temperature sensor detected 125°C or higher.
trouble • Action of controller
Action of
controller
Problem that
appears on • If machine is operated as it is, PTO may be damaged.
machine
• Failure codes of VHMS system are not recorded on the trouble data of the machine monitor.
Related
• VHMS controller 7-segment LED display: n5 o 61 (codes are displayed by 2 digits)
information
• PTO oil temperature can be checked by downloading data to PC after the snapshot.

PTO oil temperature
1 overheat (when the Check PTO lubricating system. Correct, if any.
system is normal)
Defective PTO oil tem- turning starting switch ON.
perature sensor (inter-
2 P19 (male) Oil temperature Resistance
nal disconnection or
short circuit) 25°C 46 – 59 kz
Between (1) and (2)
100°C 3.6 – 4.0 kz
Possible harness (Disconnec- Wiring harness between CV02A (female) (2) –
causes and tion or defective con- P19 (female) (1)
standard value tact in connector) Between wiring harness of CV02A (female) (12)
in normal state – P19 (female) (2) and the grounding
GND circuit) Between wiring harness of CV02A (female) (2) –
P19 (female) (1) and the grounding
CV02A Oil temperature Resistance
Defective VHMS
5 25°C 46 – 59 kz
controller Between (2) and (12)
100°C 3.6 – 4.0 kz
— Min. 1 Mz
sis ground
26 PC2000-8
Circuit diagram related to PTO oil temperature sensor
PC2000-8 27
Failure code [B@HANS] Hydr. Oil Overheat 1

User code Failure code Hydr. Oil Overheat
Trouble
— B@HANS (Pump controller 2 system)
Contents of
• While engine was running, signal of hydraulic oil temperature sensor input 102°C or higher.
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, hydraulic components may be seized.
machine
• If hydraulic oil temperature monitor on the machine monitor lights up in red while the engine is run-
Related ning, this failure code will be recorded.
information • Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring func-
tion. (Code 04401: Hydraulic oil temperature, 04403: Hydraulic oil temperature sensor voltage)

Hydr. Oil Overheat
Check the hydraulic oil for overheating. If it has been overheated, find out
1 (when system is nor-
the cause and check the hydraulic equipment for damage, then repair.
mal)
Defective hydraulic oil Hydraulic oil
P22 (male) Resistance
2 temperature sensor temperature
Possible
causes and (Internal short circuit) Between (1) – (2) 90 – 3.5 kz
standard value Between (2) – 10 – 100°C
in normal state Min. 1 Mz
chassis ground
3
(Short circuit with GND Wiring harness between CP04 (female) (9) –
P22 (female) (1) and chassis ground
Defective pump out troubleshooting.
4
controller 2
Between CP04 (4) – (9) Voltage Min. 4.5 V
28 PC2000-8
Circuit diagram related to hydraulic oil temperature sensor
PC2000-8 29
Failure code [B@HAZK] Low Hydraulic Oil Level (or change of VHMS-
LED display from n5 to 52) 1
User code Failure code Low Hydraulic Oil Level
Trouble
— B@HAZK (VHMS controller system)
Contents of
• Hydraulic oil level sensor detected the low level.
trouble
Action of
controller
Problem that
machine

Hydraulic oil low level
1 (when the system is Check the level of hydraulic oil tank. If low level, add hydraulic oil.
normal)
level sensor (internal P39 (male) Oil level Resistance
2
disconnection or short Value in normal state Max. 1 z
circuit) Between (1) and (2) Value when oil level is
Min. 1 Mz
low
3
standard value tion or defective con- Between wiring harness CV02B (female) (2) –
Resistance Max. 1 z
in normal state tact in connector) P39 (female) (1)
GND circuit) Between wiring harness CV02B (female) (2) –
P39 (female) (1)
Defective VHMS P39 (male) Oil level Resistance
5
controller Value in normal state Max. 1 z
Between (1) and (2) Value when oil level is
Min. 1 Mz
low
30 PC2000-8
Circuit diagram related to hydraulic oil level sensor
PC2000-8 31
Failure code [CA111] ECM Critical Internal Failure 1

User code Failure code ECM Critical Internal Failure
Trouble
E10 CA111 (Engine controller system)
Contents of
• Controller has abnormality in it.
trouble
Action of
• Blinks warning lamp and sounds alarm buzzer.
controller
Problem that
• Machine continues operation normally but may stop suddenly or may not able to start again once it
appears on
stops.
machine
Related
information

Defective circuit Circuit breaker may be defective. Check it directly. (If fuse is broken or cir-
1
breaker cuit breaker is turned OFF, circuit probably has ground fault.)
Disconnection in wir- turning starting switch ON.
ing harness (Discon-
Wiring harness between CE03 (female) (3) –
2 nection in wiring or Resistance Max. 1 z
battery (+)
Possible defective contact in
connector) Wiring harness between CE03 (female) (1) –
ground
standard value
GND circuit) Wiring harness between CE03 (female) (3) –
battery (+)
Defective engine out troubleshooting.
4
controller CE03 Voltage
Between (3) – (1) 20 – 30 V
32 PC2000-8
Circuit diagram related to engine controller power supply
PC2000-8 33
Failure code [CB111] ECM Critical Internal Failure 1

User code Failure code ECM Critical Internal Failure
Trouble
E10 CB111 (Engine controller system)
Contents of
• Controller has abnormality in it.
trouble
Action of
controller
Problem that
appears on
stops.
machine
Related
information

Defective circuit Circuit breaker may be defective. Check it directly. (If fuse is broken or cir-
1
breaker cuit breaker is turned OFF, circuit probably has ground fault.)
Wiring harness between CE06 (female) (3) – bat-
tery (+)
Possible defective
contact in connector) Wiring harness between CE06 (female) (1) –
ground
standard value
GND circuit) Wiring harness between CE06 (female) (3) –
battery (+) and ground
4
Between (3) – (1) 20 – 30 V
34 PC2000-8
PC2000-8 35
Failure code [CA115] Eng. Ne and Bkup Speed Sens Error 1

User code Failure code Eng. Ne and Bkup Speed Sens Error
Trouble
Contents of • Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
trouble cuit.
Action of
• Flashes warning lamp and turns on alarm buzzer.
controller
Problem that
• Engine does not start (during engine stop).
appears on
• Engine stops (during engine running).
machine
Related
information

Defective Ne speed
1 Carry out troubleshooting of [CA689].
sensor circuit
Defective Bkup speed
2 Carry out troubleshooting of [CA778].
sensor circuit
Defective Ne speed Since a mounting section of Ne speed sensor can be suspected to be
Possible 3 sensor mounting sec- defective, directly check the mounting section. (Defective installation of
causes and tion sensor itself, internal defect of flywheel, etc.)
standard value Since a mounting section of Bkup speed sensor can be suspected to be
in normal state Bkup speed sensor
4 defective, directly check the mounting section. (Defective installation of
mounting section
sensor itself, internal defect of supply pump, etc.)
Defective connection
The defective (wrong) connections of Ne speed sensor and Bkup speed
5 of sensor
sensor can be suspected. Directly check them.
(wrong connection)
Defective engine Engine controller can be suspected to be defective if no problem is found
6
controller in causes 1 – 5 (since this is an internal defect, it cannot be diagnosed).
36 PC2000-8
Failure code [CB115] Eng. Ne and Bkup Speed Sens Error 1

User code Failure code Eng. Ne and Bkup Speed Sens Error
Trouble
Contents of • Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
trouble cuit.
Action of
controller
Problem that
• Engine does not start (during engine stop).
appears on
• Engine stops (during engine running).
machine
Related
information

Defective Ne speed
1 Carry out troubleshooting of [CB689].
sensor circuit
Defective Bkup speed
2 Carry out troubleshooting of [CB778].
sensor circuit
Defective Ne speed Since a mounting section of Ne speed sensor can be suspected to be
Possible 3 sensor mounting sec- defective, directly check the mounting section. (Defective installation of
causes and tion sensor itself, internal defect of flywheel, etc.)
standard value Since a mounting section of Bkup speed sensor can be suspected to be
in normal state Bkup speed sensor
4 defective, directly check the mounting section. (Defective installation of
mounting section
sensor itself, internal defect of supply pump, etc.)
Defective connection
The defective (wrong) connections of Ne speed sensor and Bkup speed
5 of sensor
sensor can be suspected. Directly check them.
(wrong connection)
6
PC2000-8 37
Failure code [CA122] Chg Air Press Sensor High Error 1

User code Failure code Chg Air Press Sensor High Error
Trouble
Contents of
• Excessively high voltage is detected at circuit of charge pressure (boost pressure) sensor.
trouble
Action of • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
controller • Flashes warning lamp and turns on alarm buzzer.
Problem that
appears on • Acceleration performance of engine deteriorates.
machine
• The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring
Related
function. (Code: 36501 Boost pressure sensor voltage)
information
• Duplication of failure code: turn ON the starting switch.

Defective sensor If failure code [CA227] is displayed at the same time, carry out trouble-
1
power source circuit shooting for it first.
a Prepare with starting switch OFF, and diagnose with starting switch ON
or with engine started.
PIM Voltage
Defective charge pres-
2 sure (boost pressure) Between (1) – (3) Power source 4.75 – 5.25 V
sensor (internal defect) Since the sensor voltage is measured with the harness being connected, if
the voltage is abnormal, first check the harness and the controller to make
it sure if there is no other cause of the trouble, and then judge the sensor
voltage.
a Prepare with starting switch OFF and diagnose with starting switch still
OFF.
Disconnection in wir- Wiring harness between ENG (L) (female) (37) –
ing harness Resistance Max. 1 z
PIM (female) (1)
3 (disconnection or
defective contact of Resistance Max. 1 z
connectors) PIM (female) (2)
Resistance Max. 1 z
PIM (female) (3)
Possible a Prepare with starting switch OFF and diagnose with starting switch still
causes and OFF.
standard value Defective harness Between ground and wiring harness between
in normal state Resistance Min. 1 Mz
grounding ENG (L) (female) (37) – PIM (female) (1)
4
(contact with ground Between ground and wiring harness between
circuit) ENG (L) (female) (44) – PIM (female) (2)
Between ground and wiring harness between
ENG (L) (female) (47) – PIM (female) (3)
OFF.
Between wiring harness from ENG (L) (female)
(37) to PIM (female) (1) and wiring harness from Resistance Min. 1 Mz
Harness short ENG (L) (female) (44) to PIM (female) (2)
5 (Harness internal Between wiring harness from ENG (L) (female)
short) (37) to PIM (female) (1) and wiring harness from Resistance Min. 1 Mz
ENG (L) (female) (47) to PIM (female) (3)
(44) to PIM (female) (3) and wiring harness from Resistance Min. 1 Mz
ENG (L) (female) (47) to PIM (female) (3)
Defective engine or with engine started.
6
Between (37) – (47) Power source 4.75 – 5.25 V
38 PC2000-8
Circuit diagram related to charge pressure sensor
PC2000-8 39
Failure code [CA123] Chg Air Press Sensor Low Error 1

User code Failure code Chg Air Press Sensor Low Error
Trouble
Contents of
• Excessively low voltage is detected at circuit of charge pressure (boost pressure) sensor.
trouble
Action of • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
Problem that
appears on • Acceleration performance of engine deteriorates.
machine
• The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring
Related
function. (Code: 36501 Boost pressure sensor voltage)
information
Possible Cause Standard value in normal state/Remarks on troubleshooting

causes and
standard value Defective sensor If failure code [CA187] is displayed at the same time, carry out trouble-
1
in normal state
40 PC2000-8
Failure code [CA131] Throttle Sensor High Error 1

User code Failure code Throttle Sensor High Error
Trouble
Contents of
• High voltage was detected in throttle sensor signal circuit.
trouble
• If abnormality occurs while starting switch is ON, controller fixes sensor to value just before occur-
rence of abnormality and continues operation.
Action of
• If starting switch is turned ON while there is abnormality, controller fixes sensor to 100% value and
controller
continues operation.
Problem that
appears on • Engine speed cannot be controlled with fuel dial.
machine
• Fuel dial signal voltage can be checked with monitoring function
Related
(Code: 03000 Fuel dial voltage)
information
• Method of reproducing failure code: Turn starting switch ON.

Defective decelerator
If failure code [CA2185] is also displayed, carry out troubleshooting for it
1 sensor power supply
first.
system
Defective fuel dial DEC (male) Resistance
2
(Internal defect) Between (1) – (3) 4.0 – 6.0 kz
Between (2) – (1) 0.25 – 5.0 kz
Between (2) – (3) 0.25 – 5.0 kz
Disconnection in wir- Wiring harness between CE02 (female) (22) –
ing harness (Discon- Resistance Max. 1z
P20 (female) (1)
Possible 3 nection in wiring or
causes and defective contact in Resistance Max. 1z
connector) P20 (female) (2)
standard value
in normal state Wiring harness between CE02 (female) (23) –
Resistance Max. 1z
P20 (female) (3)
Ground fault in wiring Resistance Min. 1 Mz
P20 (female) (1)
P20 (female) (2)
P20 (female) (3)
Defective engine CE02 Voltage
5
controller
Between (9) – (23) Signal 0.5 – 4.5 V
42 PC2000-8
Circuit diagram related to decelerator pedal sensor
PC2000-8 43
Failure code [CA132] Throttle Sensor Low Error 1

User code Failure code Throttle Sensor Low Error
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of throttle sensor.
trouble
• Operates with the fixed value that is same as the value just before the abnormality is detected, if
abnormality occurs with the starting switch in the ON position.
Action of
• If the starting switch is turned to the ON position in as-is abnormal condition, the controller operates
controller
with 100% value.
Problem that
appears on • Engine speed cannot be controlled by fuel dial.
machine
• The signal voltage of fuel dial can be checked in monitoring mode.
Related
(Code: 03000 Fuel dial)
information

causes and
1
power supply circuit shooting for it first.
in normal state
44 PC2000-8
Failure code [CA135] Eng Oil Press Sensor High Error 1

User code Failure code Eng Oil Press Sensor High Error
Trouble
CALL E02 CA135 (Engine controller system)
Contents of
• Excessively high voltage is detected at oil pressure sensor circuit.
trouble
Action of • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
Problem that
appears on
machine
• The signal voltage of engine oil pressure sensor can be checked in monitoring function.
Related
(Code: 37201 Engine oil pressure sensor voltage)
information

Defective sensor If failure code [CA187] or [CA227] is displayed at the same time, carry out
1
power source circuit troubleshooting for it first.
POIL Voltage
Defective oil pressure
2 sensor Between (1) – (2) Power source 4.75 – 5.25 V
(internal defect) Since the sensor voltage is measured with the harness being connected, if
voltage.
OFF.
Disconnection in wir- Wiring harness between ENG (L) (female) (37) –
ing harness Resistance Max. 1 z
POIL (female) (1)
3 (disconnection or
defective contact of Resistance Max. 1 z
connectors) POIL (female) (3)
Resistance Max. 1 z
POIL (female) (2)
Possible a Prepare with starting switch OFF and diagnose with starting switch still
causes and OFF.
standard value Defective harness Between ground and wiring harness between
grounding ENG (L) (female) (37) – POIL (female) (1)
4
circuit) ENG (L) (female) (47) – POIL (female) (3)
ENG (L) (female) (13) – POIL (female) (2)
OFF.
(37) to POIL (female) (1) and wiring harness from Resistance Min. 1 Mz
Harness short ENG (L) (female) (47) to POIL (female) (3)
short) (37) to POIL (female) (1) and wiring harness from Resistance Min. 1 Mz
ENG (L) (female) (13) to POIL (female) (2)
(47) to POIL (female) (2) and wiring harness from Resistance Min. 1 Mz
ENG (L) (female) (13) to POIL (female) (3)
Defective engine or with engine started.
6
46 PC2000-8
Circuit diagram related to oil pressure sensor
PC2000-8 47
Failure code [CA141] Eng Oil Press Sensor Low Error 1

User code Failure code Eng Oil Press Sensor Low Error
Trouble
Contents of
• Excessively low voltage is detected at oil pressure sensor circuit.
trouble
Action of • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
Problem that
appears on
machine
• The signal voltage of engine oil pressure sensor can be checked in monitoring function.
Related
(Code: 37201 Engine oil pressure sensor voltage)
information

causes and
1
in normal state
48 PC2000-8
Failure code [CA144] Coolant Temp Sens High Error 1

User code Failure code Coolant Temp Sens High Error
Trouble
Contents of
• Excessively high voltage is detected at signal circuit of coolant temperature sensor.
trouble
Action of • Operates with a fixed coolant temperature (90°C).
Problem that
appears on • Exhaust gas color becomes white.
machine
• The signal voltage of coolant temperature sensor can be checked in monitoring function.
Related
(Code: 04105 Coolant temperature sensor voltage)
information

Defective coolant OFF.
1 temperature sensor
TWTR (male) Coolant temperature Resistance
(Internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Disconnection in wiring OFF.
harness
2 (disconnection or Resistance Max. 1 z
TWTR (female) (A)
defective contact of
connectors) Wiring harness among ENG (L) (female) (38) –
Resistance Max. 1 z
JB – TWTR (female) (B)
Possible Harness short OFF.
causes and 3 (Harness internal Between ENG (L) (female) (15) – all pins of ENG
standard value short) (L) (female) (with all connectors in the harness Resistance Min. 1 Mz
in normal state disconnected)
Since the connections among coolant temperature sensor – engine har-
ness – engine controller are suspected to be defective, check for a defec-
tive connection.
Defective wiring har-
4 • Connector is loose, lock is broken, seal is broken
ness connector
• Pin is corroded, bent, broken, pushed in, expanded.
• Moisture in connector, entry of dirt or sand, etc., and insufficient insula-
tion
Defect in other loca- OFF.
5 tions than engine con-
ENG (L) (female) Coolant temperature Resistance
troller
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
Defective engine Engine controller is possibly defective if no problem is found in causes 1 –
6
controller 5. (Since this is an internal defect, it cannot be diagnosed.)
50 PC2000-8
PC2000-8 51
Failure code [CA145] Coolant Temp Sens Low Error 1

User code Failure code Coolant Temp Sens Low Error
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of coolant temperature sensor.
trouble
Action of • Operates with a fixed coolant temperature (90°C).
Problem that
machine
Related • The signal voltage of coolant temperature sensor can be checked in monitoring function.
information (Code: 04105 Coolant temperature sensor voltage)

Defective coolant OFF.
1 temperature sensor
TWTR (male) Coolant temperature Resistance
(Internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Defective harness
OFF.
2 grounding (contact with
ground circuit) Resistance Min. 1 Mz
ENG (L) (female) (15) – TWTR (female) (A)
Harness short OFF.
Possible 3 (Harness internal Between ENG (L) (female) (15) – all pins of ENG
causes and short) (L) (female) (with all connectors in the harness Resistance Min. 1 Mz
standard value disconnected)
in normal state Since the connections among coolant temperature sensor – engine har-
ness – engine controller are suspected to be defective, check for a defec-
tive connection.
ness connector
tion
ENG (L) (female) Coolant temperature Resistance
troller
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
6
52 PC2000-8
PC2000-8 53
Failure code [CA153] Chg Air Temp Sensor High Error 1

User code Failure code Chg Air Temp Sensor High Error
Trouble
Contents of • Excessively high voltage is detected at signal circuit of charge temperature (boost temperature)
trouble sensor.
Action of
• Operates with a fixed charge temperature (boost temperature) (70°C).
controller
Problem that
machine
• The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
Related
monitoring function. (Code: 18501 Boost temperature sensor voltage)
information

Defective charge tem- OFF.
perature (boost tem- TIM (male) Air boost temperature Resistance
1
perature)
sensor (internal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground In all range Min. 1 Mz
Disconnection in wir- OFF.
ing harness (discon- Wiring harness between ENG (L) (female) (23) –
nection or defective TIM (female) (A)
contact of connectors) Wiring harness between ENG (L) (female) (47) –
Resistance Max. 1 z
TIM (female) (B)
Possible Harness short OFF.
causes and 3 (Harness internal Between ENG (L) (female) (23) – all pins of ENG
standard value short) (L) (female) (with all connectors in the harness Resistance Min. 1 Mz
in normal state disconnected)
Since the connections among charge temperature (boost temperature)
sensor – engine harness – engine controller are suspected to be defec-
tive, check for a defective connection.
ness connector
tion
ENG (L) (female) Air boost temperature Resistance
troller
Between (23) – (47) 10 – 100°C 0.5 – 20 kz
6
54 PC2000-8
Circuit diagram related to charge temperature sensor
PC2000-8 55
Failure code [CA154] Chg Air Temp Sensor Low Error 1

User code Failure code Chg Air Temp Sensor Low Error
Trouble
Contents of • Excessively low voltage is detected at signal circuit of charge temperature (boost temperature) sen-
trouble sor.
Action of
• Operates with a fixed charge temperature (boost temperature) (70°C).
controller
Problem that
machine
• The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
Related
monitoring function. (Code: 18501 Boost temperature sensor voltage)
information

Defective charge tem- OFF.
perature (boost tem- TIM (male) Air boost temperature Resistance
1
perature) sensor
(internal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground In all range Min. 1 Mz
Defective harness
OFF.
2 grounding (contact with
ground circuit) Resistance Min. 1 Mz
ENG (L) (female) (23) – TIM (female) (A)
Harness short OFF.
Possible 3 (Harness internal Between ENG (L) (female) (23) – all pins of ENG
causes and short) (L) (female) (with all connectors in the harness Resistance Min. 1 Mz
standard value disconnected)
in normal state Since the connections among charge temperature (boost temperature)
sensor – engine harness – engine controller are suspected to be defec-
tive, check for a defective connection.
ness connector
tion
5 tions than engine con- ENG (L) (female) Air boost temperature Resistance
troller Between (23) – (47) 10 – 100°C 0.5 – 20 kz
Between (23) – ground In all range Min. 1 Mz
6
56 PC2000-8
Circuit diagram related to charge temperature sensor
PC2000-8 57
Failure code [CA187] Sens Supply 2 Volt Low Error 1

User code Failure code Sens Supply 2 Volt Low Error
Trouble
Contents of
• Low voltage was detected in sensor power supply (2) (5 V) circuit.
trouble
• Ambient pressure sensor sets ambient temperature to default value (52.44 kPa {0.5 kg/cm2}) and
• Oil pressure sensor sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues opera-
Action of
tion.
controller
• Charge pressure sensor fixes charge pressure to (400 kPa {4.1 kg/cm2}) and continues operation.
• Bkup sensor operates with Ne speed sensor signal.
Problem that
appears on • Output lowers.
machine
Related
information

causes and
standard value Carry out troubleshooting for failure code [CA227].
in normal state
Failure code [CB187] Sens Supply 2 Volt Low Error 1

Trouble
Contents of
trouble
Action of • Bkup sensor operates with Ne speed sensor signal.
controller • Blinks warning lamp and sounds alarm buzzer.
Problem that
machine
Related
information

causes and
standard value Carry out troubleshooting for failure code [CB227].
in normal state
58 PC2000-8
Failure code [CA212] Eng Oil Temp Sensor High Error 1

User code Failure code Eng Oil Temp Sensor High Error
Trouble
Contents of
• High voltage was detected in engine oil temperature sensor circuit.
trouble
Action of
• Sets oil temperature to default value (100°C) and continues operation.
controller
Problem that
appears on
machine
Related
information

Defective oil tempera- turning starting switch ON.
1 ture sensor (Internal
TOIL (male) Oil temperature Resistance
defect)
Between (A) – (B) 0 – 100°C 0.5 – 36 kz
Possible 2 nection in wiring or Resistance Max. 1 z
TOIL (female) (A)
causes and defective contact in
connector) Wiring harness between ENG (L) (female) (47) –
in normal state TOIL (female) (B)
TOIL (female) (A)
Defective engine turning starting switch ON.
4
controller ENG (L) Oil temperature Resistance
(17) – (47) 0 – 100°C 0.5 – 36 kz
60 PC2000-8
Circuit diagram related to engine oil temperature sensor
PC2000-8 61
Failure code [CA213] Eng Oil Temp Sensor Low Error 1

User code Failure code Eng Oil Temp Sensor Low Error
Trouble
Contents of
• Low voltage was detected in engine oil temperature sensor circuit.
trouble
Action of
• Sets oil temperature to default value (100°C) and continues operation.
controller
Problem that
appears on
machine
Related
information

causes and
in normal state
62 PC2000-8
SEN02096-00
© 2006 KOMATSU
All Rights Reserved
64
SEN02097-00
PC2000-8

PC2000-8 20001 and up
Failure code [CA221] Ambient Press Sens High Error ........................................................................ 4
Failure code [CA222] Ambient Press Sens Low Error ......................................................................... 6
Failure code [CA227] Sens Supply 2 Volt High Error........................................................................... 8
Failure code [CB227] Sens Supply 2 Volt High Error......................................................................... 10
Failure code [CA234] Eng Over Speed .............................................................................................. 12
Failure code [CA238] Ne Speed Sens Supply Volt Error ................................................................... 14
Failure code [CB238] Ne Speed Sens Supply Volt Error ................................................................... 16
Failure code [CA263] Fuel Temp Sensor High Error.......................................................................... 18
Failure code [CB263] Fuel Temp Sensor High Error.......................................................................... 20
Failure code [CA265] Fuel Temp Sensor Low Error........................................................................... 21
Failure code [CB265] Fuel Temp Sensor Low Error........................................................................... 21
Failure code [CA271] IMV/PCV1 Short Error ..................................................................................... 22
Failure code [CB271] IMV/PCV1 Short Error ..................................................................................... 24
Failure code [CA272] IMV/PCV1 Open Error..................................................................................... 26
Failure code [CB272] IMV/PCV1 Open Error..................................................................................... 28
PC2000-8 1
Failure code [CA273] PCV2 Short Error............................................................................................. 30

Failure code [CB273] PCV2 Short Error............................................................................................. 32
Failure code [CA274] PCV2 Open Error ............................................................................................ 34
Failure code [CB274] PCV2 Open Error ............................................................................................ 36
Failure code [CA322] Inj #1(L#1) Open/Short Error ........................................................................... 38
Failure code [CA342] Calibration Code Incompatibility ...................................................................... 50
Failure code [CB342] Calibration Code Incompatibility ...................................................................... 50
Failure code [CA351] Injectors Drive Circuit Error ............................................................................. 52
Failure code [CB351] Injectors Drive Circuit Error ............................................................................. 54
Failure code [CA352] Sens Supply 1 Volt Low Error.......................................................................... 56
Failure code [CB352] Sens Supply 1 Volt Low Error.......................................................................... 56
Failure code [CA386] Sens Supply 1 Volt High Error ......................................................................... 58
Failure code [CB386] Sens Supply 1 Volt High Error ......................................................................... 60
Failure code [CA441] Battery Voltage Low Error................................................................................ 62
Failure code [CB441] Battery Voltage Low Error................................................................................ 62
Failure code [CA442] Battery Voltage High Error ............................................................................... 63
Failure code [CB442] Battery Voltage High Error ............................................................................... 63
Failure code [CA449] Rail Press Very High Error............................................................................... 64
Failure code [CB449] Rail Press Very High Error............................................................................... 64
2 PC2000-8

Failure code [CA221] Ambient Press Sens High Error 1
User code Failure code Ambient Press Sens High Error
Trouble
Contents of
• Excessively high voltage is detected at signal circuit of atmospheric pressure sensor.
trouble
Action of • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
Problem that
appears on • Output decreases.
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
Related
(Code: 37401 Atmospheric pressure sensor voltage)
information

Defective sensor If failure code [CA352] or [CA386] is displayed at the same time, carry out
1
power source circuit troubleshooting for it first.
a Prepare with starting switch OFF and diagnose with starting switch ON.
PAMB Voltage
Defective atmospheric
2 pressure sensor Between (2) – (3) Signal 0.5 – 4.5 V
voltage.
OFF.
Resistance Max. 1 z
harness (disconnection PAMB (female) (1)
3
or defective contact of Wiring harness between ENG (L) (female) (3) –
connectors) Resistance Max. 1 z
PAMB (female) (2)
Possible Wiring harness between ENG (L) (female) (38) –
PAMB (female) (3)
standard value a Prepare with starting switch OFF and diagnose with starting switch still
in normal state OFF.
Defective harness Resistance Min. 1 Mz
ENG (L) (female) (37) – PAMB (female) (1)
4 grounding (contact
with ground circuit) Between ground and wiring harness between
OFF.
(37) to PAMB (female) (1) and wiring harness Resistance Min. 1 Mz
Harness short from ENG (L) (female) (3) to PAMB (female) (2)
short) (37) to PAMB (female) (1) and wiring harness Resistance Min. 1 Mz
from ENG (L) (female) (38) to PAMB (female) (3)
(3) to PAMB (female) (2) and wiring harness from Resistance Min. 1 Mz
ENG (L) (female) (38) to PAMB (female) (3)
4 PC2000-8

Possible a Prepare with starting switch OFF, and diagnose with starting switch ON
causes and or with engine started.
standard value Defective engine ENG (L) Voltage
6
in normal state controller
Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38) 0.5 – 4.5 V
Circuit diagram related to atmospheric pressure sensor
PC2000-8 5
Failure code [CA222] Ambient Press Sens Low Error 1

User code Failure code Ambient Press Sens Low Error
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of atmospheric pressure sensor.
trouble
Action of • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
Problem that
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
Related
(Code: 37401 Atmospheric pressure sensor voltage)
information

causes and
standard value Carry out troubleshooting of failure code [CA221].
in normal state
6 PC2000-8
Failure code [CA227] Sens Supply 2 Volt High Error 1

User code Failure code Sens Supply 2 Volt High Error
Trouble
Contents of
• Excessively high voltage is detected in sensor power source (2) (5V) circuit.
trouble
• Operates using Ne speed sensor signal instead of Bkup speed sensor signal.
• Operate oil pressure sensor with oil pressure at default value (250 kPa {2.5 kg/cm2})
Action of
• Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.5 kg/cm2})
controller
• Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}).
Problem that
machine
Related
information

Defective related Check the codes that are displayed at the same time. If any other codes
1
circuits are displayed, carry out troubleshooting for those codes.
Bkup speed sensor G connector
Disconnect the devices Engine oil pressure
on the right one at a POIL connector
Defective sensor sensor
2 time.
(internal defect) Atmospheric pressure
If the code disappears, PAMB connector
that device is internally sensor
defective. Charge pressure sen-
PIM connector
sor
ing harness
Possible each sensor (female)
causes and connectors) Wiring harness between ENG (L) (female) (47) –
Resistance Max. 1 z
standard value each sensor (female)
in normal state a Prepare with starting switch OFF and diagnose with starting switch still
Defective harness OFF.
grounding Between ground and wiring harness between
4 Resistance Min. 1 Mz
(contact with ground ENG (L) (female) (37) – each sensor (female)
circuit) Between ground and wiring harness between
ENG (L) (female) (47) – each sensor (female)
OFF.
Harness short
5 (Harness internal
short) (37) to each sensor (female) and wiring harness
from ENG (L) (female) (47) to each sensor
(female)
Defective engine
6 ENG (L) Voltage
controller
Between (37) – (47) 4.75 – 5.25 V
8 PC2000-8
Circuit diagram related to sensor power source (2) (5V)
PC2000-8 9
Failure code [CB227] Sens Supply 2 Volt High Error 1

Trouble
Contents of
• High voltage was detected in sensor power supply (2) (5 V) circuit.
trouble
Action of
• Bkup speed sensor operates with Ne speed sensor signal.
controller
Problem that
machine
Related
information

Related defective
1 If another code is also displayed, carry out troubleshooting for it.
system
Defective sensor When device at right is
2
(Internal defect) disconnected, if error
Bkup speed sensor G connector
code disappears, that
device has defect in it.
Wiring harness between ENG (R) (female) (37) –
each sensor (female)
defective contact in
connector) Wiring harness between ENG (R) (female) (47) –
causes and
standard value
in normal state Ground fault in wiring
4 harness (Contact with Resistance Min. 1 Mz
GND circuit)
Short circuit in wiring
5 harness (with another Between wiring harness from ENG (R) (female)
wiring harness) (37) to each sensor (female) and wiring harness
from ENG (R) (female) (47) to each sensor
(female)
6
controller ENG (R) Voltage
Between (37) – (47) 4.75 – 5.25 V
10 PC2000-8
Circuit diagram related to sensor power source (2) (At right bank)
PC2000-8 11
Failure code [CA234] Eng Over Speed 1

User code Failure code Eng Over Speed
Trouble
Contents of • The engine speed exceeds upper control limit speed.
trouble • Flashes warning lamp and turns on alarm buzzer.
Action of
• Stops operation of injector until the engine speed drops to the normal speed.
controller
Problem that
appears on • Engine speed fluctuates.
machine
Related • The engine speed can be checked in monitoring function. (Code: 01000 Engine speed)
information • Duplication of failure code: Start engine and operate at high idle.

Defective related Check the codes that are displayed at the same time. If any other codes
Possible 1
circuits are displayed, carry out troubleshooting for those codes.
causes and
The improper usage of equipped machine can be suspected. Instruct the
standard value 2 Improper usage
proper usage.
in normal state
3
12 PC2000-8
Failure code [CA238] Ne Speed Sens Supply Volt Error 1

User code Failure code Ne Speed Sens Supply Volt Error
Trouble
Contents of
• Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
trouble
Action of • Controls using Bkup speed sensor signal.
Problem that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appears on
• Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
Related
information

OFF.
Defective Ne speed Disconnect a device
1 sensor shown on the right.
(internal defect) If the failure code disap- Ne speed sensor Ne connector
pears, that device is
internally defective.
ing harness
Ne (female) (1)
Possible connectors) Wiring harness between ENG (L) (female) (48) –
Resistance Max. 1 z
causes and Ne (female) (2)
in normal state Defective harness OFF.
(contact with ground ENG (L) (female) (16) – Ne (female) (1)
ENG (L) (female) (48) – Ne (female) (2)
Harness short OFF.
short) (16) to Ne (female) (1) and wiring harness from Resistance Min. 1 Mz
ENG (L) (female) (48) to Ne (female) (2)
Defective engine
5 ENG (L) Voltage
controller
Between (16) – (48) 4.75 – 5.25 V
14 PC2000-8
Circuit diagram related to Ne speed sensor power source
PC2000-8 15
Failure code [CB238] Ne Speed Sens Supply Volt Error 1

User code Failure code Ne Speed Sens Supply Volt Error
Trouble
Contents of
• Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
trouble
Action of • Controls using Bkup speed sensor signal.
Problem that
appears on
machine
Related
information

OFF.
Defective Ne speed Disconnect a device
1 sensor shown on the right.
(internal defect) If the failure code disap- Ne speed sensor Ne connector
pears, that device is
internally defective.
ing harness
Ne (female) (1)
Possible connectors) Wiring harness between ENG (R) (female) (48) –
Resistance Max. 1 z
causes and Ne (female) (2)
in normal state Defective harness OFF.
(contact with ground ENG (L) (female) (16) – Ne (female) (1)
ENG (R) (female) (48) – Ne (female) (2)
Harness short OFF.
short) (16) to Ne (female) (1) and wiring harness from Resistance Min. 1 Mz
ENG (R) (female) (48) to Ne (female) (2)
Defective engine
5 Between ENG (L) (16) – Voltage
controller
ENG (R) (48) 4.75 – 5.25 V
16 PC2000-8
Circuit diagram related to Ne speed sensor power source
PC2000-8 17
Failure code [CA263] Fuel Temp Sensor High Error 1

User code Failure code Fuel Temp Sensor High Error
Trouble
Contents of
• Excessively high voltage is detected at fuel temperature sensor circuit.
trouble
Action of
• Operates with a fixed fuel temperature (95°C).
controller
Problem that
appears on
machine
Related • The signal voltage of engine fuel temperature sensor can be checked in monitoring function.
information (Code: 14201 Engine fuel temperature sensor voltage)

Defective fuel tempera- OFF.
1 ture sensor (internal
TFUEL (male) Fuel temperature Resistance
defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
ing harness
Possible 2 (disconnection or Resistance Max. 1 z
TFUEL (female) (A)
causes and defective contact of
connectors) Wiring harness between ENG (L) (female) (47) –
in normal state TFUEL (female) (B)
(contact with ground ENG (L) (female) (30) – TFUEL (female) (A)
circuit) a Prepare with starting switch OFF and diagnose with starting switch still
OFF.
Defective engine ENG (L) (female) Fuel temperature Resistance
4
controller Between (30) – (47) 10 – 100°C 0.6 – 20 kz
18 PC2000-8
Circuit diagram related to fuel temperature sensor
PC2000-8 19
Failure code [CB263] Fuel Temp Sensor High Error 1

User code Failure code Fuel Temp Sensor High Error
Trouble
Contents of
• Excessively high voltage is detected at fuel temperature sensor circuit.
trouble
Action of
• Operates with a fixed fuel temperature (95°C).
controller
Problem that
appears on
machine
Related • The signal voltage of engine fuel temperature sensor can be checked in monitoring function.
information (Code: 14201 Engine fuel temperature sensor voltage)

Defective fuel tempera- OFF.
1 ture sensor (internal
TFUEL (male) Fuel temperature Resistance
defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
ing harness
Possible 2 (disconnection or Resistance Max. 1 z
TFUEL (female) (A)
causes and defective contact of
connectors) Wiring harness between ENG (R) (female) (47) –
in normal state TFUEL (female) (B)
(contact with ground ENG (R) (female) (30) – TFUEL (female) (A)
circuit) a Prepare with starting switch OFF and diagnose with starting switch still
OFF.
Defective engine ENG (R) (female) Fuel temperature Resistance
4
controller Between (30) – (47) 10 – 100°C 0.6 – 20 kz
Circuit diagram related to fuel temperature sensor
20 PC2000-8
Failure code [CA265] Fuel Temp Sensor Low Error 1

User code Failure code Fuel Temp Sensor Low Error
Trouble
Contents of
• Low voltage was detected in fuel temperature sensor circuit.
trouble
• Substitutes coolant temperature sensor.
Action of
• If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95°C) and
controller
Problem that
appears on
machine
Related
information

causes and
in normal state
Failure code [CB265] Fuel Temp Sensor Low Error 1

User code Failure code Fuel Temp Sensor Low Error
Trouble
Contents of
• Low voltage was detected in fuel temperature sensor circuit.
trouble
• Substitutes coolant temperature sensor.
Action of
• If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95°C) and
controller
Problem that
appears on
machine
Related
information

causes and
in normal state
PC2000-8 21
Failure code [CA271] IMV/PCV1 Short Error 1

User code Failure code IMV/PCV1 Short Error
Trouble
Contents of
• Short circuit occurred in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump turning starting switch ON.
1 PCV1 PCV1 (male) Resistance
(Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) – ground Min. 1 Mz
PCV1 (female) (1)
Possible GND circuit)
causes and Resistance Min. 1 Mz
PCV1 (female) (2)
standard value
Hot short (Contact with
3 24V circuit) in wiring Voltage Max. 1 V
PCV1 (female) (1)
harness
Voltage Max. 1 V
PCV1 (female) (2)
Defective engine
controller
Between (4) – (5) 2.3 – 5.3 z
22 PC2000-8
Circuit diagram related to supply pump PCV1
PC2000-8 23
Failure code [CB271] IMV/PCV1 Short Error 1

User code Failure code IMV/PCV1 Short Error
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

PCV1 (female) (1)
PCV1 (female) (2)
standard value
PCV1 (female) (1)
harness
Voltage Max. 1 V
PCV1 (female) (2)
Defective engine
4 ENG (R) (female) Resistance
controller
Between (4) – (5) 2.3 – 5.3 z
24 PC2000-8
PC2000-8 25
Failure code [CA272] IMV/PCV1 Open Error 1

User code Failure code IMV/PCV1 Open Error
Trouble
Contents of
• Disconnection occurred in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

PCV1 PCV1 (male) Resistance
1
tion) Between (1) – (2) 2.3 – 5.3 z
PCV1 (female) (1)
Possible defective
contact in connector) Wiring harness between ENG (L) (female) (5) –
PCV1 (female) (2)
standard value
PCV1 (female) (1)
GND circuit)
PCV1 (female) (2)
Defective engine
controller
Between (4) – (5) 2.3 – 5.3 z
26 PC2000-8
PC2000-8 27
Failure code [CB272] IMV/PCV1 Open Error 1

User code Failure code IMV/PCV1 Open Error
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

PCV1 PCV1 (male) Resistance
1
tion) Between (1) – (2) 2.3 – 5.3 z
PCV1 (female) (1)
Possible defective
contact in connector) Wiring harness between ENG (R) (female) (5) –
PCV1 (female) (2)
standard value
PCV1 (female) (1)
GND circuit)
PCV1 (female) (2)
Defective engine
controller
Between (4) – (5) 2.3 – 5.3 z
28 PC2000-8
PC2000-8 29
Failure code [CA273] PCV2 Short Error 1

User code Failure code PCV2 Short Error
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

PCV2 (female) (1)
PCV2 (female) (2)
standard value
PCV2 (female) (1)
harness
Voltage Max. 1 V
PCV2 (female) (2)
Defective engine
controller
Between (9) – (10) 2.3 – 5.3 z
30 PC2000-8
PC2000-8 31
Failure code [CB273] PCV2 Short Error 1

User code Failure code PCV2 Short Error
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

PCV2 (female) (1)
PCV2 (female) (2)
standard value
PCV2 (female) (1)
harness
Voltage Max. 1 V
PCV2 (female) (2)
Defective engine
controller
Between (9) – (10) 2.3 – 5.3 z
32 PC2000-8
PC2000-8 33
Failure code [CA274] PCV2 Open Error 1

User code Failure code PCV2 Open Error
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1 PCV2 (Internal discon-
PCV2 (male) Resistance
nection)
Between (1) – (2) 2.3 – 5.3 z
PCV2 (female) (1)
Possible connector) Wiring harness between ENG (L) (female) (10) –
Resistance Max. 1 z
causes and PCV2 (female) (2)
PCV2 (female) (1)
GND circuit)
PCV2 (female) (2)
Defective engine ENG (L) (female) Resistance
4
controller
Between (9) – (10) 2.3 – 5.3 z
34 PC2000-8
PC2000-8 35
Failure code [CB274] PCV2 Open Error 1

User code Failure code PCV2 Open Error
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1 PCV2 (Internal discon-
PCV2 (male) Resistance
nection)
Between (1) – (2) 2.3 – 5.3 z
PCV2 (female) (1)
Possible connector) Wiring harness between ENG (R) (female) (10) –
Resistance Max. 1 z
causes and PCV2 (female) (2)
PCV2 (female) (1)
GND circuit)
PCV2 (female) (2)
Defective engine ENG (R) (female) Resistance
4
controller
Between (9) – (10) 2.3 – 5.3 z
36 PC2000-8
Failure code [CA322] Inj #1(L#1) Open/Short Error 1

User code Failure code Inj #1(L#1) Open/Short Error
Trouble
Contents of
• A disconnection or short circuit has occurred in injector No. 1 circuit.
trouble
Action of
controller
Problem that
• Output decreases.
appears on
• Speed is not stable.
machine
Related
information

OFF.
Defective injector No. 1 CN1 (male) Resistance
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
Between (1), (2) and ground Min. 1 Mz
harness
CN1 (female) (1)
Resistance Max. 1 z
Possible CN1 (female) (2)
causes and a Prepare with starting switch OFF and diagnose with starting switch still
standard value OFF.
in normal state Defective harness
3 grounding (contact with Resistance Min. 1 Mz
ENG (L) (female) (45) – CN1 (female) (1)
ground circuit)
Defective another cylin-
If multiple failure codes are displayed for injector malfunction, carry out
4 der injector or wiring
troubleshooting for them, too.
harness
OFF.
5
controller
Between (45) – (53) 0.4 – 1.1 z
38 PC2000-8
Circuit diagram related to injector No. 1
PC2000-8 39

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness
CN5 (female) (1)
Resistance Max. 1 z
standard value OFF.
3 grounding (contact Resistance Min. 1 Mz
with ground circuit)
Defective another cyl-
4 inder injector or wiring
harness
OFF.
5
controller
Between (46) – (60) 0.4 – 1.1 z
40 PC2000-8
PC2000-8 41

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness
CN3 (female) (1)
Resistance Max. 1 z
standard value OFF.
harness
OFF.
5
controller
Between (55) – (52) 0.4 – 1.1 z
42 PC2000-8
PC2000-8 43

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness
CN6 (female) (1)
Resistance Max. 1 z
standard value OFF.
harness
OFF.
5
controller
Between (57) – (59) 0.4 – 1.1 z
44 PC2000-8
PC2000-8 45

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness
CN2 (female) (1)
Resistance Max. 1 z
standard value OFF.
harness
OFF.
5
controller
Between (54) – (51) 0.4 – 1.1 z
46 PC2000-8
PC2000-8 47

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness
CN4 (female) (1)
Resistance Max. 1 z
standard value OFF.
harness
OFF.
5
controller
Between (56) – (58) 0.4 – 1.1 z
48 PC2000-8
PC2000-8 49
Failure code [CA342] Calibration Code Incompatibility 1

User code Failure code Calibration Code Incompatibility
Trouble
Contents of
• Data mismatch occurred in engine controller.
trouble
Action of
controller
Problem that
appears on • Engine cannot be started or operated.
machine
Related
information

causes and
in normal state
Failure code [CB342] Calibration Code Incompatibility 1

User code Failure code Calibration Code Incompatibility
Trouble
Contents of
• Data mismatch occurred in engine controller.
trouble
Action of
controller
Problem that
appears on • Engine cannot be started or operated.
machine
Related
information

causes and
in normal state
50 PC2000-8
Failure code [CA351] Injectors Drive Circuit Error 1

User code Failure code Injectors Drive Circuit Error
Trouble
Contents of
• Abnormality has occurred in injector drive circuit.
trouble
Action of • Operates with limited output. (Limits common rail pressure.)
Problem that
machine
Related
information

Check the failure codes (codes for injector system trouble) that are dis-
Defective related
1 played at the same time. If any other codes are displayed, carry out trou-
circuits
bleshooting for those codes.
Since a fuse or breaker of equipped machine side can be suspected to be
defective, directly check them.
2 Defective breaker
(If fuse is blown, or breaker is shut off, it is highly possible that a defective
grounding, etc. has occurred in the circuit.)
Possible Disconnection in wiring OFF.
causes and harness
Wiring harness between CE03 (female) (3) (4) –
standard value 3 (disconnection or Resistance Max. 1 z
battery (+)
in normal state defective contact of
connectors) Wiring harness between CE03 (female) (1) (2)
Resistance Max. 1 z
and ground
CE03 (female) (3) (4) – battery (+)
Defective engine
5 CE03 Voltage
controller
Between (3), (4) – (1), (2) 20 – 30 V
52 PC2000-8
Circuit diagram related to controller power source
PC2000-8 53
Failure code [CB351] Injectors Drive Circuit Error 1

User code Failure code Injectors Drive Circuit Error
Trouble
Contents of
• Abnormality occurred in injector drive circuit.
trouble
Action of • Limits output and continues operation (Limits common rail pressure).
Problem that
machine
Related
information

Related defective If another code (code of injector system abnormality) is also displayed,
1
system carry out troubleshooting for it.
Fuse or circuit breaker on applicable machine side may be defective.
Defective circuit
2 Check them directly. (If fuse is broken or circuit breaker is turned OFF, cir-
breaker
cuit probably has ground fault.)
harness (Disconnec-
Possible Wiring harness between CE06 (female) (3), (4) –
causes and battery (+)
tive contact in
standard value connector) Wiring harness between CE06 (female) (1), (2) –
Resistance Max. 1 z
in normal state ground
Wiring harness between CE06 (female) (3), (4) –
battery (+)
5
Between (3), (4) – (1), (2) 20 – 30 V
54 PC2000-8
PC2000-8 55
Failure code [CA352] Sens Supply 1 Volt Low Error 1

Trouble
Contents of
trouble
Action of • Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
Problem that
machine
Related
information

causes and
in normal state
Failure code [CB352] Sens Supply 1 Volt Low Error 1

Trouble
Contents of
trouble
Problem that
machine
Related
information

causes and
in normal state
56 PC2000-8
Failure code [CA386] Sens Supply 1 Volt High Error 1

Trouble
Contents of
trouble
Problem that
machine
Related
information

Related defective
system
2
(Internal defect) disconnected, if error Left common rail
PFUEL connector
code disappears, that pressure sensor
Disconnection in wiring
harness (Disconnec- Resistance Max. 1 z
PFUEL (female) (1)
tive contact in Wiring harness between ENG (L) (female) (25) –
Resistance Max. 1 z
connector) PFUEL (female) (2)
Resistance Max. 1 z
PFUEL (female) (3)
Possible Ground fault in wiring Resistance Min. 1 Mz
PFUEL (female) (1)
causes and 4 harness (Contact with
standard value GND circuit) Wiring harness between ENG (L) (female) (25) –
in normal state PFUEL (female) (2)
PFUEL (female) (3)
Between wiring harness between ENG (L)
(female) (33) – PFUEL (female) (1) and wiring
harness between ENG (L) (female) (25) –
PFUEL (female) (2)
5 harness (with another
wiring harness) (female) (33) – PFUEL (female) (1) and wiring
PFUEL (female) (3)
PFUEL (female) (3)
6
Between (33) – (47) 4.75 – 5.25 V
58 PC2000-8
Circuit diagram related to sensor power supply 1 (5V)
PC2000-8 59
Failure code [CB386] Sens Supply 1 Volt High Error 1

Trouble
Contents of
trouble
Problem that
machine
Related
information

Related defective
system
2
(Internal defect) disconnected, if error Right common rail
PFUEL connector
code disappears, that pressure sensor
PFUEL (female) (1)
tive contact in Wiring harness between ENG (R) (female) (25) –
Resistance Max. 1 z
Resistance Max. 1 z
PFUEL (female) (3)
Possible Ground fault in wiring Resistance Min. 1 Mz
PFUEL (female) (1)
standard value GND circuit) Wiring harness between ENG (R) (female) (25) –
in normal state PFUEL (female) (2)
PFUEL (female) (3)
Between wiring harness between ENG (R)
harness between ENG (R) (female) (25) –
PFUEL (female) (2)
5 harness (with another
wiring harness) (female) (33) – PFUEL (female) (1) and wiring
PFUEL (female) (3)
PFUEL (female) (3)
6
controller ENG (R) Voltage
Between (33) – (47) 4.75 – 5.25 V
60 PC2000-8
Circuit diagram related to sensor power supply (1) (5V)
PC2000-8 61
Failure code [CA441] Battery Voltage Low Error 1

User code Failure code Battery Voltage Low Error
Trouble
Contents of
• Low voltage was detected in power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on
stops.
machine
Related
information

causes and
in normal state
Failure code [CB441] Battery Voltage Low Error 1

User code Failure code Battery Voltage Low Error
Trouble
Contents of
• Low voltage was detected in power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on
stops.
machine
Related
information

causes and
in normal state
62 PC2000-8
Failure code [CA442] Battery Voltage High Error 1

User code Failure code Battery Voltage High Error
Trouble
Contents of
• High voltage was detected in power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on
stops.
machine
Related
information

causes and
in normal state
Failure code [CB442] Battery Voltage High Error 1

User code Failure code Battery Voltage High Error
Trouble
Contents of
• High voltage was detected in power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on
stops.
machine
Related
information

causes and
in normal state
PC2000-8 63
Failure code [CA449] Rail Press Very High Error 1

User code Failure code Rail Press Very High Error
Trouble
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (Level 2).
trouble
Problem that
machine
Related
information

causes and
in normal state
Failure code [CB449] Rail Press Very High Error 1

User code Failure code Rail Press Very High Error
Trouble
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (Level 2).
trouble
Problem that
machine
Related
information

causes and
in normal state
64 PC2000-8
SEN02097-00

© 2006 KOMATSU
All Rights Reserved
66
SEN02098-00
PC2000-8

PC2000-8 20001 and up
Failure code [CA451] Rail Press Sensor High Error ............................................................................ 4
Failure code [CB451] Rail Press Sensor High Error ............................................................................ 6
Failure code [CA452] Rail Press Sensor Low Error ............................................................................. 8
Failure code [CB452] Rail Press Sensor Low Error ............................................................................. 8
Failure code [CA553] Rail Press High Error......................................................................................... 9
Failure code [CB553] Rail Press High Error....................................................................................... 10
Failure code [CA554] Rail Press Sensor In Range Error ....................................................................11
Failure code [CB554] Rail Press Sensor In Range Error ....................................................................11
Failure code [CA559] Rail Press Low Error ....................................................................................... 12
Failure code [CB559] Rail Press Low Error ....................................................................................... 16
Failure code [CA689] Eng Ne Speed Sensor Error............................................................................ 20
Failure code [CB689] Eng Ne Speed Sensor Error............................................................................ 22
Failure code [CA691] Intake Air Temp Sens High Error ..................................................................... 24
Failure code [CA692] Intake Air Temp Sens Low Error...................................................................... 26
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................................ 27
PC2000-8 1
Failure code [CB731] Eng Bkup Speed Sens Phase Error ................................................................ 27
Failure code [CA757] All Persistent Data Lost Error .......................................................................... 28
Failure code [CB757] All Persistent Data Lost Error .......................................................................... 28
Failure code [CA778] Eng Bkup Speed Sensor Error ........................................................................ 30
Failure code [CB778] Eng Bkup Speed Sensor Error ........................................................................ 32
Failure code [CA781] CEN Communication Error .............................................................................. 34
Failure code [CB781] CEN Communication Error .............................................................................. 36
Failure code [CA1117] Persistent Data Lost Error.............................................................................. 37
Failure code [CB1117] Persistent Data Lost Error.............................................................................. 37
Failure code [CA1257] Harness Key Error ......................................................................................... 38
Failure code [CB1257] Harness Key Error ......................................................................................... 39
Failure code [CB1548] Inj #7(R#1) Open/Short Error ........................................................................ 40
Failure code [CB1551] Inj #10(R#4) Open/Short Error ...................................................................... 44
Failure code [CB1552] Inj #11(R#5) Open/Short Error....................................................................... 46
Failure code [CB1553] Inj #12(R#6) Open/Short Error ...................................................................... 48
Failure code [CA1633] KOMNET Data link Time out Error ................................................................ 52
Failure code [CA2185] Throt Sens Sup Volt High Error ..................................................................... 54
Failure code [CA2186] Throt Sens Sup Volt Low Error ...................................................................... 56
Failure code [CA2249] Rail Press Very Low Error ............................................................................. 57
Failure code [CB2249] Rail Press Very Low Error ............................................................................. 57
Failure code [CA2555] Grid Heater Relay Volt Low Error .................................................................. 58
Failure code [CA2556] Grid Heater Relay Volt High Error ................................................................. 60
2 PC2000-8

Failure code [CA451] Rail Press Sensor High Error 1
User code Failure code Rail Press Sensor High Error
Trouble
Contents of
• Excessively high voltage has occurred in the common rail pressure sensor circuit.
trouble
Action of • Operates with limited output.(Limits common rail pressure.)
Problem that
machine
Related • The signal voltage of the common rail pressure sensor can be checked with the monitoring function.
information (Code: 36401 Common rail pressure sensor voltage)

Defective sensor If failure code [CA352] or [CA386] is displayed, carry out troubleshooting
1
power source circuit for it first.
PFUEL Voltage
Defective common rail Between (1) – (3) Power source 4.75 – 5.25 V
2 pressure sensor Between (2) – (3) Signal 0.25 – 4.6 V
voltage.
Resistance Max. 1 z
harness (disconnection PFUEL (female) (1)
3
or defective contact of Wiring harness between ENG (L) (female) (25) –
connectors) Resistance Max. 1 z
PFUEL (female) (2)
PFUEL (female) (3)
standard value turning starting switch ON.
in normal state
ENG (L) (female) (33) – PFUEL (female) (1)
(33) to PFUEL (female) (1) and wiring harness
from ENG (L) (female) (25) to PFUEL (female)
(2)
Harness short
5 (Harness internal
short) (33) to PFUEL (female) (1) and wiring harness
(3)
(25) to PFUEL (female) (2) and wiring harness
(3)
4 PC2000-8

Possible a Prepare with starting switch OFF, and diagnose with starting switch ON
causes and or with engine started.
standard value Defective engine ENG (L) Voltage
6
Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
PC2000-8 5
Failure code [CB451] Rail Press Sensor High Error 1

User code Failure code Rail Press Sensor High Error
Trouble
Contents of
• High voltage was detected in common rail pressure sensor circuit.
trouble
Problem that
machine
Related • Signal voltage of common rail pressure sensor can be checked with monitoring function
information (Code: 36404: Common rail pressure sensor voltage).

Defective sensor If code [CB352] or [CB386] is displayed, carry out troubleshooting for it
1
engine and carry out troubleshooting.
PFUEL Voltage
Defective common rail
2 pressure sensor
(Internal defect) Between (2) – (3) Signal 0.25 – 4.6 V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for another
cause of trouble, and then judge.
Disconnection in wiring Wiring harness between ENG (R) (female) (33) –
PFUEL (female) (1)
tive contact in Resistance Max. 1 z
Resistance Max. 1 z
Possible PFUEL (female) (3)
in normal state Wiring harness between ENG (R) (female) (33) –
PFUEL (female) (1)
PFUEL (female) (2)
PFUEL (female) (3)
PFUEL (female) (2)
5 harness (with another Between wiring harness between ENG (R)
wiring harness) Resistance Min. 1 Mz
PFUEL (female) (3)
PFUEL (female) (3)
6 PC2000-8

Possible a Prepare with starting switch OFF, then turn starting switch ON and carry
causes and out troubleshooting.
standard value Defective engine ENG (R) Voltage
6
Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
PC2000-8 7
Failure code [CA452] Rail Press Sensor Low Error 1

User code Failure code Rail Press Sensor Low Error
Trouble
Contents of
• Low voltage was detected in common rail pressure sensor circuit.
trouble
Problem that
machine

causes and
in normal state
Failure code [CB452] Rail Press Sensor Low Error 1

User code Failure code Rail Press Sensor Low Error
Trouble
Contents of
• Low voltage was detected in common rail pressure sensor circuit.
trouble
Problem that
machine

causes and
in normal state
8 PC2000-8
Failure code [CA553] Rail Press High Error 1

User code Failure code Rail Press High Error
Trouble
Contents of
• Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related • Common rail pressure can be checked with the monitoring function.
information (Code: 36400 Common rail pressure)

Defective related cir- Check the codes that are displayed at the same time. If any other codes
1
cuits are displayed, carry out troubleshooting for those codes.
Improper fuel has been Since the use of improper fuel can be suspected, check the fuel.
2
used. (Viscosity is too high)
Defective electrical Since an electrical defect of common rail pressure sensor is suspected,
3 system of common rail carry out troubleshooting for the following code.
Possible
pressure sensor [CA451]
causes and
Defective mechanical
standard value Since a mechanical defect of common rail pressure sensor is suspected,
in normal state 4 system of common rail
directly check the sensor.
pressure sensor
Defective overflow Since a damage of spring, wear of seat or sticking of ball is suspected,
5
valve directly check them.
Clogged overflow pip-
6 Since an overflow piping is suspected to be clogged, directly check it.
ing
Defective pressure Since a mechanical defect of pressure limiter is suspected, directly check
7
limiter the limiter.
PC2000-8 9
Failure code [CB553] Rail Press High Error 1

User code Failure code Rail Press High Error
Trouble
Contents of
• Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine

1
Improper fuel has been Since the use of improper fuel can be suspected, check the fuel.
2
used. (Viscosity is too high)
Defective electrical Since an electrical defect of common rail pressure sensor is suspected,
3 system of common rail carry out troubleshooting for the following code.
Possible
pressure sensor [CB451]
causes and
Defective mechanical
standard value Since a mechanical defect of common rail pressure sensor is suspected,
in normal state 4 system of common rail
directly check the sensor.
pressure sensor
Defective overflow Since a damage of spring, wear of seat or sticking of ball is suspected,
5
valve directly check them.
Clogged overflow pip-
6 Since an overflow piping is suspected to be clogged, directly check it.
ing
Defective pressure Since a mechanical defect of pressure limiter is suspected, directly check
7
limiter the limiter.
10 PC2000-8
Failure code [CA554] Rail Press Sensor In Range Error 1

User code Failure code Rail Press Sensor In Range Error
Trouble
Contents of
• In-range error has occurred in common rail pressure sensor circuit.
trouble
Problem that
machine
Related
information

causes and
standard value Carry out troubleshooting of [CA451].
in normal state
Failure code [CB554] Rail Press Sensor In Range Error 1

User code Failure code Rail Press Sensor In Range Error
Trouble
Contents of
• In-range error has occurred in common rail pressure sensor circuit.
trouble
Problem that
machine
Related
information

causes and
standard value Carry out troubleshooting of [CB451].
in normal state
PC2000-8 11
Failure code [CA559] Rail Press Low Error 1

User code Failure code Rail Press Low Error
Trouble
Contents of
• Loss of pressure feed (level 1) from supply pump has occurred.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
appears on
machine
Related
information

1
Improper fuel has been
2 Since the use of improper fuel is suspected, directly check the fuel.
used.
a See “Note 1” for the contents of diagnosis. See Testing and adjusting
“Testing fuel pressure” for the pressure inspection of the fuel low pres-
sure circuit.
Defective low pressure
3 Pressure in fuel low pressure
circuit device
circuit Min. 0.15 MPa
(At high idle or under the load equiv- {Min. 1.5 kg/cm2}
alent to rating (stalling))
Clogged filter or
4 a See “Note 2” for the contents of diagnosis.
strainer
Defective electrical Since an electrical defect of supply pump PCV is suspected, carry out
5 system of supply pump troubleshooting for the following codes.
PCV [CA271], [CA272], [CA273], and [CA274]
Possible
causes and Defective common rail Since a defect of common rail pressure sensor is suspected, check for a
6
standard value pressure sensor damage in harnesses.
in normal state a As for testing an amount of pressure limiter leak, see testing and adjust-
ing “Testing fuel return and leak amount”.
Defective pressure
7 Max. 10 cc/min.
limiter
Pressure limiter leak amount [Equivalent to rated operation
(stalling)]
a As for the test relating to return (spill) limit amount of injector, see Test-
ing and adjusting “Testing fuel return and leak amount”.
Speed under the conditions which
are equivalent to rated operation Injector return (spill) limit amount
(stalling)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Supply pump can be suspected to be defective if no problem is found in
9 Defective supply pump
causes 1 – 8.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-
pressure feed”.
12 PC2000-8
Note 1: When low-pressure circuit equipment is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
PC2000-8 13
Check sheet for no-pressure feed
Model Operation No.

Model and serial No. # Date inspected / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual inspections Pass Fail

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Inspections with machine monitor (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 800 – 850
*1 Engine speed High idle rpm 1,955 – 2,005
Equivalent to rating rpm 2,000
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3 — — —
tion rate
Command for common
*4 Equivalent to rating MPa
4 rail pressure
Fuel pressure in
common rail
Low idle CA — — —
Command for
*6 High idle CA — — —
fuel injection timing
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Coolant temperature
*8 Low idle °C — — —
(high temperature)
Coolant temperature
(low temperature)
*10 Fuel temperature Low idle °C — — —
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
Cylinder No. 1 Low idle rpm — — —
5 Cylinder No. 2 Low idle rpm — — —

*11
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa Min. 0.15
6
cuit lent to rating (stalling) {kg/cm2} {Min. 1.5}
14 PC2000-8
D. Inspection of strainer and filter Pass Fail

7 Visual inspection of strainer
8 Visual inspection of gauze filter
9 Visual inspection of fuel filter
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return Standard value

Condition for inspection Unit Measured value Pass Fail
amount (reference value)
Pressure limiter Under the load equivalent to rating
11 cc/min Max 10
leak amount (stalling)
Equivalent to rating: 1,600 rpm cc/min 960
Equivalent to rating: 1,700 rpm cc/min 1,020 Rotation speed:
12 Injector return amount Equivalent to rating: 1,800 rpm cc/min 1,080
Equivalent to rating: 1,900 rpm cc/min 1,140 Return amount:
Equivalent to rating: 2,000 rpm cc/min 1,200
Inspection items *1 – *10 of B-4:

When inspecting with the monitoring function, see “Monitoring code table”.
Inspection items *11 of B-5:
When inspecting with the monitoring function, see “Adjustment mode table”.
Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder
PC2000-8 15
Failure code [CB559] Rail Press Low Error 1

User code Failure code Rail Press Low Error
Trouble
Contents of
• Loss of pressure feed (level 1) from supply pump has occurred.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
appears on
machine
Related
information

1
Improper fuel has been
2 Since the use of improper fuel is suspected, directly check the fuel.
used.
a See “Note 1” for the contents of diagnosis. See Testing and adjusting
“Testing fuel pressure” for the pressure inspection of the fuel low pres-
sure circuit.
Defective low pressure
3 Pressure in fuel low pressure
circuit device
circuit Min. 0.15 MPa
(At high idle or under the load equiv- {Min. 1.5 kg/cm2}
alent to rating (stalling))
Clogged filter or
4 a See “Note 2” for the contents of diagnosis.
strainer
Defective electrical Since an electrical defect of supply pump PCV is suspected, carry out
5 system of supply pump troubleshooting for the following codes.
PCV [CB271], [CB272], [CB273], and [CB274]
Possible
causes and Defective common rail Since a defect of common rail pressure sensor is suspected, check for a
6
standard value pressure sensor damage in harnesses.
in normal state a As for testing an amount of pressure limiter leak, see testing and adjust-
ing “Testing fuel return and leak amount”.
Defective pressure
7 Max. 10 cc/min.
limiter
Pressure limiter leak amount [Equivalent to rated operation (stall-
ing)]
a As for the test relating to return (spill) limit amount of injector, see Test-
ing and adjusting “Testing fuel return and leak amount”.
Speed under the conditions which
are equivalent to rated operation Injector return (spill) limit amount
(stalling)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Supply pump can be suspected to be defective if no problem is found in
9 Defective supply pump
causes 1 – 8.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-
pressure feed”.
16 PC2000-8
Note 1: When low-pressure circuit equipment is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
PC2000-8 17
Check sheet for no-pressure feed
Model Operation No.

Model and serial No. # Date inspected / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual inspections Pass Fail

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Inspections with machine monitor (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 800 – 850
*1 Engine speed High idle rpm 1,955 – 2,005
Equivalent to rating rpm 1,800
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3 — — —
tion rate
Command for common
4 rail pressure
Fuel pressure in
common rail
Low idle CA — — —
Command for
*6 High idle CA — — —
fuel injection timing
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Coolant temperature
(high temperature)
Coolant temperature
(low temperature)
*10 Fuel temperature Low idle °C — — —
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
5 Cylinder No. 2 Low idle rpm — — —

*11
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa Min. 0.15
6
cuit lent to rating (stalling) {kg/cm2} {Min. 1.5}
18 PC2000-8
D. Inspection of strainer and filter Pass Fail

7 Visual inspection of strainer
8 Visual inspection of gauze filter
9 Visual inspection of fuel filter
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return Standard value

Condition for inspection Unit Measured value Pass Fail
amount (reference value)
Pressure limiter Under the load equivalent to rating
11 cc/min Max 10
leak amount (stalling)
Equivalent to rating: 1,600 rpm cc/min 960
Equivalent to rating: 1,700 rpm cc/min 1,020 Rotation speed:
12 Injector return amount Equivalent to rating: 1,800 rpm cc/min 1,080
Equivalent to rating: 1,900 rpm cc/min 1,140 Return amount:
Equivalent to rating: 2,000 rpm cc/min 1,200
Inspection items *1 – *10 of B-4:

When inspecting with the monitoring function, see “Monitoring code table”.
Inspection items *11 of B-5:
When inspecting with the monitoring function, see “Adjustment mode table”.
Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder
PC2000-8 19
Failure code [CA689] Eng Ne Speed Sensor Error 1

User code Failure code Eng Ne Speed Sensor Error
Trouble
Contents of
• Abnormal signal of the engine Ne speed sensor has been detected.
trouble
Action of • Operates using Bkup speed sensor signal.
Problem that
appears on
machine
Related
information

Defective sensor If failure code [CA238] is displayed at the same time, carry out trouble-
1
harness Resistance Max. 1 z
NE (female) (1)
2 (disconnection or
defective contact of Wiring harness between ENG (L) (female) (48) –
Resistance Max. 1 z
NE (female) (2)
connectors)
Resistance Max. 1 z
NE (female) (3)
Defective harness Between ground and wiring harness between
grounding ENG (L) (female) (16) – NE (female) (1)
3
circuit) ENG (L) (female) (48) – NE (female) (2)
Possible Between ground and wiring harness between
causes and ENG (L) (female) (27) – NE (female) (3)
(16) to NE (female) (1) and wiring harness from Resistance Min. 1 Mz
Harness short ENG (L) (female) (48) to NE (female) (2)
short) (16) to NE (female) (1) and wiring harness from Resistance Min. 1 Mz
ENG (L) (female) (27) to NE (female) (3)
ENG (L) (female) (27) to NE (female) (3)
Defective mounting of
sensor or defective Since defective mounting of Ne speed sensor (improper gap) or defective
5
parts for speed detec- parts for speed detection (flywheel) can be suspected, directly check it.
tion
Engine Ne speed sensor can be suspected to be defective if no problem is
Defective engine Ne
6 found in causes 1 – 5 (since this is an internal defect, it cannot be diag-
speed sensor
nosed).
7
20 PC2000-8
Circuit diagram related to engine Ne speed sensor
PC2000-8 21
Failure code [CB689] Eng Ne Speed Sensor Error 1

User code Failure code Eng Ne Speed Sensor Error
Trouble
Contents of
• Abnormal signal of the engine Ne speed sensor has been detected.
trouble
Action of • Operates using Bkup speed sensor signal.
Problem that
appears on
machine
Related
information

Defective sensor If failure code [CB238] is displayed at the same time, carry out trouble-
1
NE (female) (1)
2 (disconnection or
defective contact of Wiring harness between ENG (R) (female) (48) –
Resistance Max. 1 z
NE (female) (2)
connectors)
Resistance Max. 1 z
NE (female) (3)
Defective harness Between ground and wiring harness between
grounding ENG (L) (female) (16) – NE (female) (1)
3
circuit) ENG (R) (female) (48) – NE (female) (2)
causes and ENG (R) (female) (27) – NE (female) (3)
Harness short ENG (R) (female) (48) to NE (female) (2)
short) (16) to NE (female) (1) and wiring harness from Resistance Min. 1 Mz
ENG (R) (female) (27) to NE (female) (3)
Between wiring harness from ENG (R) (female)
ENG (R) (female) (27) to NE (female) (3)
sensor or defective Since defective mounting of Ne speed sensor (improper gap) or defective
5
parts for speed detec- parts for speed detection (flywheel) can be suspected, directly check it.
tion
Engine Ne speed sensor can be suspected to be defective if no problem is
Defective engine Ne
6 found in causes 1 – 5 (since this is an internal defect, it cannot be diag-
speed sensor
nosed).
7
22 PC2000-8
Circuit diagram related to engine Ne speed sensor
PC2000-8 23
Failure code [CA691] Intake Air Temp Sens High Error 1

User code Failure code Intake Air Temp Sens High Error
Trouble
Contents of
• Intake air temperature sensor circuit detected high voltage.
trouble
Action of
• Fixes intake air temperature (25°C) and continues operation.
controller
Problem that
appears on
machine
Related • Input state from the intake air temperature sensor can be checked with monitoring function
information (Code: 18400 Intake air temperature, Code: 18401 Intake air temperature sensor voltage)

Defective charge tem- turning starting switch ON.
1 perature sensor (Inter- TAMB Intake air temperature Resistance
nal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground All range Min. 1 Mz
harness (Disconnec-
Possible Wiring harness between ENG (L) (female) (43) –
2 tion in wiring or defec- Resistance Max. 1z
causes and TAMB (female) (A)
tive contact in
connector) Resistance Max. 1z
in normal state TAMB (female) (B)
GND circuit) Wiring harness between ENG (L) (female) (43) –
TAMB (female) (A)
4
controller ENG (L) (female) Intake air temperature Resistance
Between (43) – (47) 10 – 100°C 0.5 – 20 kz
24 PC2000-8
Circuit diagram related to intake air temperature sensor
PC2000-8 25
Failure code [CA692] Intake Air Temp Sens Low Error 1

User code Failure code Intake air temperature sensor abnormally low level (Only left bank): Low
Trouble
E15 CA692 voltage detection (Engine controller system)
Contents of
• Intake air temperature sensor circuit detected low voltage.
trouble
Action of
• Fixes intake air temperature (25°C) and continues operation.
controller
Problem that
appears on
machine
Related
information

causes and
in normal state
26 PC2000-8
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1

User code Failure code Eng Bkup Speed Sens Phase Error
Trouble
Contents of
• Abnormal phase has been detected in the engine Bkup sensor circuit.
trouble
Action of • Operates using engine Ne speed sensor signal.
Problem that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appears on
• Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
machine
Related
information

Since a defect of engine Ne speed sensor can be suspected, carry out
Possible Defective engine Ne
1 troubleshooting for the following code.
causes and speed sensor circuit
[CA689]
standard value
in normal state Since a defect of engine Bkup speed sensor can be suspected, carry out
Defective engine Bkup
speed sensor system
[CA778]
Failure code [CB731] Eng Bkup Speed Sens Phase Error 1

User code Failure code Eng Bkup Speed Sens Phase Error
Trouble
Contents of
• Abnormal phase has been detected in the engine Bkup sensor circuit.
trouble
Action of • Operates using engine Ne speed sensor signal.
Problem that
appears on
machine
Related
information

Since a defect of engine Ne speed sensor can be suspected, carry out
Possible Defective engine Ne
causes and speed sensor circuit
[CB689]
standard value
in normal state Since a defect of engine Bkup speed sensor can be suspected, carry out
speed sensor system
[CB778]
PC2000-8 27
Failure code [CA757] All Persistent Data Lost Error 1

User code Failure code All Persistent Data Lost Error
Trouble
Contents of
• Loss of all data in engine controller has been detected.
trouble
Action of
controller
Problem that
appears on • The engine cannot be started, or cannot be operated.
machine
Related
information

causes and
standard value Carry out troubleshooting of [CA111].
in normal state
Failure code [CB757] All Persistent Data Lost Error 1

User code Failure code All Persistent Data Lost Error
Trouble
Contents of
• Loss of all data in engine controller has been detected.
trouble
Action of
controller
Problem that
appears on • The engine cannot be started, or cannot be operated.
machine
Related
information

causes and
standard value Carry out troubleshooting of [CB111].
in normal state
28 PC2000-8
Failure code [CA778] Eng Bkup Speed Sensor Error 1

User code Failure code Eng Bkup Speed Sensor Error
Trouble
Contents of
• Abnormal engine Bkup speed sensor signal has been detected.
trouble
Action of • Operates using Ne speed sensor signal.
Problem that
appears on
machine
Related
information

Defective sensor If failure code [CA187] or [CA227] is displayed, carry out troubleshooting
1
power source circuit for it first.
left G (female) (1)
2 (disconnection or
defective contact of Wiring harness between ENG (L) (female) (47) –
Resistance Max. 1 z
left G (female) (2)
connectors)
Resistance Max. 1 z
left G (female) (3)
ENG (L) (female) (37) – left G (female) (1)
ENG (L) (female) (47) – left G (female) (2)
causes and ENG (L) (female) (26) – left G (female) (3)
(37) to left G (female) (1) and wiring harness Resistance Min. 1 Mz
Harness short from ENG (L) (female) (47) to left G (female) (2)
short) (37) to left G (female) (1) and wiring harness Resistance Min. 1 Mz
from ENG (L) (female) (26) to left G (female) (3)
(47) to left G (female) (2) and wiring harness Resistance Min. 1 Mz
from ENG (L) (female) (26) to left G (female) (3)
Since defective mounting of Bkup speed sensor (improper gap) or defec-
sensor or defective
5 tive parts for speed detection (in supply pump) can be suspected, directly
parts for speed detec-
check it.
tion
Engine Bkup speed sensor can be suspected to be defective if no problem
6 is found in causes 1 – 5 (since this is an internal defect, it cannot be diag-
speed sensor
nosed).
7
30 PC2000-8
Circuit diagram related to engine Bkup speed sensor
PC2000-8 31
Failure code [CB778] Eng Bkup Speed Sensor Error 1

User code Failure code Eng Bkup Speed Sensor Error
Trouble
Contents of
• Engine Bkup speed sensor signal detected abnormality.
trouble
Action of • Operates with Ne speed sensor signal
Problem that
• If engine has been running, it stops (when Ne speed sensor is also defective).
appears on
• If engine has been stopped, it cannot start (when Ne speed sensor is also defective).
machine
Related
information

Defective sensor If failure code [CB187] or [CB227] is displayed, carry out troubleshooting
1
power supply system for it first.
right G (female) (1)
tive contact in Wiring harness between ENG (R) (female) (47) –
Resistance Max. 1 z
connector)
Resistance Max. 1 z
GND circuit) Wiring harness between ENG (R) (female) (47) –
Possible Resistance Min. 1 Mz
in normal state
(female) (37) – right G (female) (1) and wiring
harness between ENG (R) (female) (47) – right G
(female) (2)
4 harness (with another Between wiring harness between ENG (R)
wiring harness) (female) (37) – right G (female) (1) and wiring
(female) (3)
(female) (47) – right G (female) (2) and wiring
(female) (3)
Defective sensor Bkup speed sensor may be installed defectively (improper clearance) or
5 installation or defec- speed sensing part (in supply pump) may be defective. Check them
tive speed sensing part directly.
Defective engine Bkup If causes 1 – 5 are not detected, engine Bkup speed sensor may be defec-
6
speed sensor tive. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective engine If causes 1 – 6 are not detected, engine controller may be defective.
7
controller (Since trouble is in system, troubleshooting cannot be carried out.)
32 PC2000-8
Circuit diagram related to engine Bkup speed sensor
PC2000-8 33
Failure code [CA781] CEN Communication Error 1

User code Failure code CEN Communication Error
Trouble
E0E CA781 (Engine controller system)
Contents of
• Communication error occurred between engine controllers (Left bank).
trouble
Action of
controller
Problem that
• During operation: Engine continues operation with 1 bank.
appears on
• When key is ON: Engine cannot be started.
machine
Related
information

harness (Disconnec-
ENG (R) (female) (8)
tive contact in
connector) Wiring harness between ENG (L) (female) (6) –
Resistance Max. 1 z
Possible a Prepare with starting switch OFF, then carry out troubleshooting without
causes and turning starting switch ON.
in normal state ENG (R) (female) (8)
GND circuit)
Defective engine
controller
Between (8) – (6) 108 – 132 z
34 PC2000-8
Circuit diagram related to communication between multiple controller
PC2000-8 35
Failure code [CB781] CEN Communication Error 1

User code Failure code CEN Communication Error
Trouble
E0E CB781 (Engine controller system)
Contents of
• Communication error occurred between engine controllers (Right bank).
trouble
Action of
controller
Problem that
• During operation: Engine continues operation with 1 bank.
appears on
• When key is ON: Engine cannot be started.
machine
Related
information

causes and
in normal state
36 PC2000-8
Failure code [CA1117] Persistent Data Lost Error 1

Error code Failure code
Trouble Persistent Data Lost Error (LH bank) (Engine controller system)
E10 CA1117
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

causes and
standard value Carry out troubleshooting [CA111].
in normal state
Failure code [CB1117] Persistent Data Lost Error 1

Error code Failure code
Trouble Persistent Data Lost Error (RH bank) (Engine controller system)
E10 CB1117
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

causes and
standard value Carry out troubleshooting [CB111].
in normal state
PC2000-8 37
Failure code [CA1257] Harness Key Error 1

User code Failure code Harness Key Error
Trouble
Contents of
• Controller of each bank disagrees with distinction wiring harness (Left bank).
trouble
Action of • Stops operation.
Problem that
appears on • When key is ON: Engine cannot be started.
machine
Related
information

tive contact in Wiring harness between CE02 (female) (7) –
Resistance Max. 1 z
Possible connector) CE02 (female) (34)
causes and
in normal state GND circuit) Between CE02 (female) (8) – ground Resistance Min. 1 Mz
3
controller Between CE02 (female) (7) – ground Resistance Min. 1 Mz
Between CE02 (female) (8) – ground Resistance Max. 1 z
Circuit diagram related to multicontroller distinction wiring harness key
38 PC2000-8
Failure code [CB1257] Harness Key Error 1

User code Failure code Harness Key Error
Trouble
E0E CB1257 (Engine controller system)
Contents of
• Controller of each bank disagrees with distinction wiring harness (Right bank).
trouble
Action of • Stops operation.
Problem that
appears on • When key is ON: Engine cannot be started.
machine
Related
information

Possible connector) CE05 (female) (34)
causes and
in normal state GND circuit) Between CE05 (female) (8) – ground Resistance Min. 1 Mz
3
controller Between CE05 (female) (7) – ground Resistance Min. 1 Mz
Between CE05 (female) (8) – ground Resistance Min. 1 Mz
Circuit diagram related to multicontroller distinction wiring harness key
PC2000-8 39
Failure code [CB1548] Inj #7(R#1) Open/Short Error 1

User code Failure code Inj #7(R#1) Open/Short Error
Trouble
Contents of
• Disconnection or short circuit occurred in injector #7 circuit.
trouble
Action of
controller
Problem that
• Output lowers.
appears on
• Engine speed is unstable.
machine
Related
information

Defective injector #7 CN1 (male) Resistance
1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness (Disconnec-
CN1 (female) (1)
tive contact in
Resistance Max. 1 z
CN1 (female) (2)
Possible
CN1 (female) (1)
GND circuit)
CN1 (female) (2)
Defective injector of
another cylinder or If failure codes of 1 or more injectors are displayed, carry out troubleshoot-
4
defective wiring har- ing for them.
ness
Defective engine
controller
Between (45) – (53) 0.4 – 1.1 z
40 PC2000-8
Circuit diagram related to injector #7 (R/B #1)
PC2000-8 41

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output lowers.
appears on
machine
Related
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness (Disconnec-
CN2 (female) (1)
tive contact in
Resistance Max. 1 z
CN2 (female) (2)
Possible
CN2 (female) (1)
GND circuit)
CN2 (female) (2)
4
ness
Defective engine
controller
Between (54) – (51) 0.4 – 1.1 z
42 PC2000-8
PC2000-8 43

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output lowers.
appears on
machine
Related
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness (Disconnec-
CN4 (female) (1)
tive contact in
Resistance Max. 1 z
CN4 (female) (2)
Possible
CN4 (female) (1)
GND circuit)
CN4 (female) (2)
4
ness
Defective engine
controller
Between (56) – (58) 0.4 – 1.1 z
44 PC2000-8
PC2000-8 45

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output lowers.
appears on
machine
Related
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness (Disconnec-
CN5 (female) (1)
tive contact in
Resistance Max. 1 z
CN5 (female) (2)
Possible
CN5 (female) (1)
GND circuit)
CN5 (female) (2)
4
ness
Defective engine
controller
Between (46) – (60) 0.4 – 1.1 z
46 PC2000-8
PC2000-8 47

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output lowers.
appears on
machine
Related
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness (Disconnec-
CN6 (female) (1)
tive contact in
Resistance Max. 1 z
CN6 (female) (2)
Possible
CN6 (female) (1)
GND circuit)
CN6 (female) (2)
4
ness
Defective engine
controller
Between (57) – (59) 0.4 – 1.1 z
48 PC2000-8
PC2000-8 49

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output lowers.
appears on
machine
Related
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness (Disconnec-
CN3 (female) (1)
tive contact in
Resistance Max. 1 z
CN3 (female) (2)
Possible
CN3 (female) (1)
GND circuit)
CN3 (female) (2)
4
ness
Defective engine
controller
Between (55) – (52) 0.4 – 1.1 z
50 PC2000-8
PC2000-8 51
Failure code [CA1633] KOMNET Data link Time out Error 1

User code Failure code KOMNET Data link Time out Error
Trouble
Contents of
• Abnormality occurred in KOMNET communication circuit to engine controller (Left bank).
trouble
Action of • Operates in default mode or holds the state set when error occurred.
Problem that
• Information may not be transmitted or received normally through KOMNET communication system
appears on
and machine may not operate normally.
machine
Related
information

Disconnection in wiring Wiring harness between CE02 (female) (46) –
CE05 (female) (46)
Resistance Max. 1 z
CE05 (female) (47)
connector)
Resistance 54 – 66 z
CE02 (female) (47)
Possible
causes and
CE05 (female) (46)
GND circuit)
CE05 (female) (47)
Defective engine Wiring harness between CE02 (female) (46) –
3 Resistance 54 – 66 z
controller CE02 (female) (47)
Resistance 54 – 66 z
CE05 (female) (47)
52 PC2000-8
Circuit diagram related to KOMNET
PC2000-8 53
Failure code [CA2185] Throt Sens Sup Volt High Error 1

User code Failure code Throt Sens Sup Volt High Error
Trouble
Contents of
• High voltage (above 5.25 V) was detected in decelerator pedal sensor power supply circuit.
trouble
• If trouble occurs while starting switch is ON, controller fixes sensor to value just before occurrence
Action of of abnormality and continues operation.
controller • If starting switch is turned ON while there is trouble, controller operates at 100% value.
Problem that
appears on • Engine speed cannot be controlled with decelerator pedal.
machine
Related
information

Defective decelerator When device at right is
1
sensor (Internal defect) disconnected, if code
Decelerator sensor DEC connector
disappears, that device
has trouble in it.
harness (Disconnec-
P20 (female) (1)
tive contact in
connector) Wiring harness between CE02 (female) (23) –
Resistance Max. 1 z
Possible P20 (female) (3)
P20 (female) (1)
GND circuit)
P20 (female) (3)
Short circuit in wiring turning starting switch ON.
4 harness (with another Between wiring harness between CE02 (female)
108 –
wiring harness) (22) – P20 (female) (1) and wiring harness Resistance
132 z
between CE02 (female) (23) – P20 (female) (3)
5
Between (22) – (23) 4.75 – 5.25 V
54 PC2000-8
Circuit diagram related to decelerator pedal sensor power supply
PC2000-8 55
Failure code [CA2186] Throt Sens Sup Volt Low Error 1

User code Failure code Throt Sens Sup Volt Low Error
Trouble
Contents of
• Excessively low voltage is detected in the decelerator pedal sensor (5V) power source circuit.
trouble
• Operates with the fixed value that is same as the value just before the abnormality is detected, if
abnormality occurs with the starting switch in the ON position.
Action of
• If the starting switch is turned to the ON position in as-is abnormal condition, the controller operates
controller
with 100% value.
Problem that
appears on • Engine speed cannot be controlled by fuel dial.
machine
Related
information

causes and
standard value 1 Carry out troubleshooting for failure code [CA2185].
in normal state
56 PC2000-8
Failure code [CA2249] Rail Press Very Low Error 1

Trouble Rail Press Very Low Error (At left bank) (Engine controller system)
E11 CA2249
Contents of
• Loss of pressure feed (level 2) occurred in the common rail circuit.
trouble
Action of • Operates with limited output.
Problem that • Engine is hard to start.
appears on • Exhaust gas color becomes black.
machine • Output decreases.

causes and
standard value 1 Carry out troubleshooting of [CA559].
in normal state
Failure code [CB2249] Rail Press Very Low Error 1

Trouble Rail Press Very Low Error (At right bank) (Engine controller system)
E11 CB2249
Contents of
• Loss of pressure feed (level 2) occurred in the common rail circuit.
trouble
Action of • Operates with limited output.
Problem that • Engine is hard to start.
appears on • Exhaust gas color becomes black.
machine • Output decreases.

causes and
standard value 1 Carry out troubleshooting of [CB559].
in normal state
PC2000-8 57
Failure code [CA2555] Grid Heater Relay Volt Low Error 1
User code Failure code Grid Heater Relay Volt Low Error
Trouble
Contents of
• Voltage low error was detected in grid heater relay circuit.
trouble
Action of
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related
information

causes and
in normal state
58 PC2000-8
Failure code [CA2556] Grid Heater Relay Volt High Error 1
User code Failure code Grid Heater Relay Volt High Error
Trouble
Contents of
• Open error was detected in intake air heater relay circuit
trouble
Action of
• Stops driving auto-preheater relay R17.
controller
Problem that
• Auto-preheater does not work (Manual preheater works).
appears on
• Engine does not start easily at low temperature.
machine
Related
information

Defective grid heater turning starting switch ON.
1 relay
R17 (male) Resistance
(Internal defect)
Between (1) – (2) 200 – 400 z
harness
2 (Disconnection in wir- Resistance Max. 1 z
R17 (female) (1)
ing or defective contact
Possible in connector) Wiring harness between CE02 (female) (42) –
Resistance Max. 1 z
causes and R17 (female) (2)
harness Wiring harness between CE02 (female) (40) –
(Short circuit with GND R17 (female) (1) and chassis ground
circuit) Wiring harness between CE02 (female) (42) –
R17 (female) (2) and chassis ground
Defective engine CE02 Heater relay Voltage
4
controller
Operating condition Max. 1 V
Between (40) – (42)
Stop condition 20 – 30 V
60 PC2000-8
Circuit diagram related to engine preheater
PC2000-8 61
SEN02098-00

© 2006 KOMATSU
All Rights Reserved
62
SEN02099-00
PC2000-8

PC2000-8 20001 and up
Failure code [D110KB] Battery Relay Drive S/C .................................................................................. 4
Failure code [D163KB] Flash Light Relay S/C ..................................................................................... 6
Failure code [D195KA] Step Light Relay Disc...................................................................................... 8
Failure code [D195KY] Step Light Relay S/C..................................................................................... 10
Failure code [D1E9KB] Wiper Drive Relay 1 S/C............................................................................... 12
Failure code [D1EAKB] Wiper Drive Relay 2 S/C .............................................................................. 14
Failure code [D1EBKB] Lower Wiper Brake Relay Short Circuit........................................................ 16
Failure code [D1ECKB] Upper Wiper Brake Relay Short Circuit ....................................................... 18
Failure code [DA22KK] Pump 1 Solenoid Power Low Error .............................................................. 20
Failure code [dA22KK] Pump 2 Solenoid Power Low Error ............................................................... 22
Failure code [DA25KP] Pump 1 Sens Supply Vol Low Error ............................................................. 24
Failure code [dA25KP] Pump 2 Sens Supply Vol Low Error .............................................................. 26
Failure code [DA26KP] 5V Sensor 2 Power Abnormality................................................................... 28
Failure code [DA29KQ] Pump 1 Model Select Abnormality ............................................................... 30
Failure code [dA29KQ] Pump 2 Model Select Abnormality................................................................ 32
PC2000-8 1
Failure code [DA2RMC] CAN Discon (Pump 1 Con Detected) .......................................................... 34

Failure code [dA2RMC] CAN Discon (Pump 2 Con Detected)........................................................... 36
Failure code [DA2TMC] Pump Comm. ECM Child Abnormality......................................................... 38
Failure code [DBB0KK] VHMS Source Voltage Error
(or change of VHMS-LED display from n9 to 01)..................................................................... 40
Failure code [DBB0KQ] VHMS Connector Mismatch
(or change of VHMS-LED display from nf to 11) ...................................................................... 42
Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02) ........... 48
Failure code [DGE5KX] Ambient Air Temp Sensor Failure
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C......................................................................... 52
Failure code [DGT3KZ] PTO Temp Sensor Failure
2 PC2000-8

Failure code [D110KB] Battery Relay Drive S/C 1
User code Failure code Battery Relay Drive S/C
Trouble
— D110KB (Pump controller 1 system)
Contents of
• Abnormal current flowed at output to battery relay drive circuit.
trouble
Action of • Turns output to battery relay drive circuit OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • There may be a trouble in writing data into the ROM (non-volatile memory) of each controller.
machine
Related • Operating condition of battery relay (ON/OFF) can be checked with monitoring function.
information (Code 03703: Controller Output 4)

Defective battery relay Battery relay (Unit) Resistance
1
(Internal short circuit)
Between BR – E Approx. 100z
Between BR – chassis ground Min. 1 Mz
causes and harness Wiring harness between CP03 (female) (4) –
standard value 2 D05 – JB112 – battery relay terminal BR or
(Short circuit with GND
in normal state circuit) between CP03 (female) (4) – starting switch ter- Resistance Min. 1 Mz
minal BR or between CP03 (female) (4) – D05
(female) (2) and chassis ground
Defective pump con- Turn starting switch
3 CP03 Voltage
troller 1 OFF.
Between (4) – 20 – 30 V
ON o OFF
chassis ground (2 – 7 sec.)
4 PC2000-8
Circuit diagram related to battery relay drive
PC2000-8 5
Failure code [D163KB] Flash Light Relay S/C 1

User code Failure code Flash Light Relay S/C
Trouble
— D163KB (Pump controller 2 system)
Contents of • Abnormal current flowed in the flash light relay circuit (the primary circuit of the relay), when power
trouble is supplied to the circuit.
• The controller turns OFF the output to the coil circuit of the flash light relay.
Action of
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Problem that
appears on • The flash light does not flash.
machine
• Operation of the flash light relay circuit (the primary side of the relay) (ON or OFF) can be checked
Related in the monitoring function. (Code No. 03701: Controller output 2)
information • This error code detects abnormality on the primary (coil) side of the flash light relay and cannot
detect abnormality on the secondary (contact) side.

Flash light relay defec- a Prepare with starting switch OFF, then carry out troubleshooting without
tive turning starting switch ON.
1
(Internal short-circuit- R13 (male) Resistance
ing) Between (1) – (2) 250 – 350 z
Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without
Possible ing harness turning starting switch ON.
2
causes and (Contact with ground- Between wiring harness between CP06 (female)
standard value ing circuit) Resistance Min. 1 Mz
(8) and R13 (female) (1) and grounding
CP06 Horn switch Voltage
Pump controller 2
3 20 – 30 V Max. 1 V
defective
Between (8) – ON (at constant cycle,
chassis ground 5 seconds)
OFF Max. 1 V
6 PC2000-8
Circuit diagram related to horn and flash light relay
PC2000-8 7
Failure code [D195KA] Step Light Relay Disc 1

User code Failure code Step Light Relay Disc
Trouble
— D195KA (Pump controller system)
Contents of • Step light relay circuit power supply is low.
trouble • Error due to FB voltage remaining under 5.7 V for 3 sec continually when commanded for OFF.
Action of
controller
Problem that
appears on • Step light is not lighting up.
machine
Related • Operating condition of step light relay (ON/OFF) can be checked with monitoring function.
information (Monitoring code: 03701, controller output 2)
Cause Standard value in normalcy and references for troubleshooting

Defective step light turning starting switch ON.
1 relay (Internal discon-
R07 (male) Resistance value
nection).
Between (1) – (2) 250 – 350 z
harness (Disconnec-
causes and 2
tion or defective con- Wiring harness between CP05 (female) (8) – Resistance
standard value Max. 1 z
tact in connector) R07 (female) (2) value
in normal state
Defective pump con- CP05 Step light switch Voltage
3
troller 2 OFF 20 – 30 V
sis ground Max. 1 V
ON
(Kept for 60 sec)
8 PC2000-8
Circuit diagram related to step light relay
PC2000-8 9
Failure code [D195KY] Step Light Relay S/C 1

User code Failure code Step Light Relay S/C
Trouble
— D195KY (Pump controller system)
Contents of • Abnormal current flowed in the step light relay circuit (the primary circuit of the relay), when power is
trouble supplied to the circuit.
• Power to the step light relay circuit is switched OFF.
Action of
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Problem that
appears on • Step light does not light up.
machine
• Operation of the step light relay circuit (the primary side of the relay) (ON or OFF) can be checked in
Related the monitoring function. (Code No. 03701: Controller output 2)
information • This error code detects abnormality on the primary (coil) side of the step light relay and cannot
detect abnormality on the secondary (contact) side.
Cause Standard value in normalcy and references for troubleshooting

Step light relay defec- turning starting switch ON.
1 tive (Internal short-cir-
R07 (male) Resistance value
cuiting)
Between (1) – (2) 250 – 350 z
ing harness
causes and 2
(Contact with ground- Between wiring harness between CP05 (female) Resistance Above 1
standard value
ing circuit) (8) and R07 (female) (2) and grounding value Mz
in normal state
Pump controller 2 CP05 Horn switch Voltage
3
defective OFF 20 – 30 V
Between (8) – chassis
ground Below 1 V
ON
(Kept for 60 sec)
10 PC2000-8
Circuit diagram related to step light
PC2000-8 11
Failure code [D1E9KB] Wiper Drive Relay 1 S/C 1

User code Failure code Wiper Drive Relay 1 S/C
Trouble
— D1E9KB (Pump controller system)
Contents of
• Abnormal current flowed to the lower wiper drive relay output system.
trouble
Action of
• Stops output.
controller
Problem that
appears on • Lower, upper wiper cannot work.
machine
Related • Lower wiper drive relay output (ON-OFF) can be checked with monitoring function.

Replace with the relay.
Lower wiper drive relay
1 Defective lower wiper
(Internal defect) "E" disappears
Turn the starting relay
Possible switch ON Defective lower wiper
"E" does not disappear
causes and relay drive circuit
GND circuit) Between wiring harness of CP06 (female) (26) –
lower wiper drive relay (SR3) and chassis ground
Defective pump con- engine and carry out troubleshooting in each case.
3
troller 2 Wiper
Between CP06 (female) (26) and chassis ground 20 – 30 V
switch ON
Note:
1) If "E" disappeared from the error screen when above 1 and 2 are checked and if the wiper operation is
not normal, adjust the lower wiper limit position.
q Monitoring code: 02208 SWITCH INPUT 5 (LOWER WIPER LIMIT SWITCH: ON)
2) Lower wiper limit switch: Adjust the position to turn it ON.
3) If the switch does not turn ON at the storage position, replace the lower wiper.
12 PC2000-8
Circuit diagram related to lower wiper drive relay
PC2000-8 13
Failure code [D1EAKB] Wiper Drive Relay 2 S/C 1

User code Failure code Wiper Drive Relay 2 S/C
Trouble
— D1EAKB (Pump controller 2 system)
Contents of
• Abnormal current flowed to the upper wiper drive relay output system.
trouble
Action of
• Stops output.
controller
Problem that
appears on • Both the upper and lower wiper cannot work.
machine
Related • Upper wiper drive relay output (ON-OFF) can be checked with monitoring function.

Upper wiper drive relay Replace with the relay.
1
(Internal defect) Normal state is recovered Defective upper wiper relay
Defective upper wiper relay drive cir-
Normal state is not recovered
Possible cuit
standard value Ground fault in wiring turning starting switch ON.
in normal state 2 harness (Contact with Between wiring harness of CP06 (female) (26) –
GND circuit) upper wiper drive relay (SR3) and chassis Resistance Min. 1 Mz
ground
3
troller 2 Wiper
Between CP06 (female) (6) and chassis ground 20 – 30 V
switch ON
14 PC2000-8
Circuit diagram related to upper wiper drive relay
PC2000-8 15
Failure code [D1EBKB] Lower Wiper Brake Relay Short Circuit 1

User code Failure code Lower Wiper Brake Relay Short Circuit
Trouble
— D1EBKB (Pump controller system)
Contents of
• Abnormal current flowed to the lower wiper brake relay output system.
trouble
Action of
• Stops output.
controller
Problem that
appears on • Lower wiper cannot work.
machine
Related • Lower wiper brake relay output (ON-OFF) can be checked with monitoring function.

Replace with the relay.
Lower wiper brake
1 Defective lower wiper
relay (internal defect) "E" disappears
Turn the starting brake relay
switch ON Defective lower wiper
"E" does not disappear
Possible brake relay drive circuit
GND circuit) lower wiper drive brake (SR3) and chassis Resistance Min. 1 Mz
ground
Defective pump con-
3 2 sec. after
troller 2
Between CP06 (female) (36) and chassis ground wiper switch 20 – 30 V
ON o OFF
Note:
1) If "E" disappeared from the error screen when above 1 and 2 are checked and if the wiper operation is
not normal, adjust the lower wiper limit position.
q Monitoring code: 02208 SWITCH INPUT 5 (LOWER WIPER LIMIT SWITCH: ON)
2) Lower wiper limit switch: Adjust the position to turn it ON.
3) If the switch does not turn ON at the storage position, replace the lower wiper.
16 PC2000-8
Circuit diagram related to lower wiper brake relay
PC2000-8 17
Failure code [D1ECKB] Upper Wiper Brake Relay Short Circuit 1

User code Failure code Upper Wiper Brake Relay Short Circuit
Trouble
— D1ECKB (Pump controller system)
Contents of
• Abnormal current flowed to the upper wiper brake relay output system.
trouble
Action of
• Stops output.
controller
Problem that
appears on • Both the upper and lower wipers cannot work.
machine
Related • Upper wiper brake relay output (ON-OFF) can be checked with monitoring function.

Upper wiper brake Replace with the relay.
1
relay (internal defect) Normal state is recovered Defective upper wiper brake relay
Defective upper wiper brake relay
Normal state is not recovered
drive circuit
Possible
GND circuit) upper wiper brake relay (SR3) and chassis Resistance Min. 1 Mz
ground
Defective pump con-
3 2 sec. after
troller 2
Between CP06 (female) (16) and chassis ground wiper switch 20 – 30 V
ON o OFF
18 PC2000-8
Circuit diagram related to upper wiper brake relay
PC2000-8 19
Failure code [DA22KK] Pump 1 Solenoid Power Low Error 1

User code Failure code Pump 1 Solenoid Power Low Error
Trouble
E0E DA22KK (Pump controller 1 system)
Contents of
• Pump controller solenoid valve is below 20 V.
trouble
Action of
• Limits engine speed to upper limit of 1,400 rpm.
controller
Problem that • If the solenoid supply voltage drops radically, the swing speed of work equipment and machine
appears on travel speed are substantially reduced.
machine • Engine speed does not rise above 1,400 rpm.
Related
• If [D110KB] is displayed, carry out troubleshooting for it first.
information

Defective circuit a If circuit breaker B24 is turned OFF, circuit probably has ground fault
1
breaker No. 2 or No. 6 etc. (See Cause 3.)
Wiring harness between C03 (female) (1), (2),
Resistance Max. 1 z
(12), (22) – A03 (male) (2)
Disconnection in wiring Wiring harness between A03 (female) (2), (4) –
B28B
2 (Disconnection in wir-
ing or defective contact Wiring harness between battery relay terminal M
Resistance Max. 1 z
in connector) – B11
Wiring harness between starting switch terminal
BR – battery relay terminal BR
causes and
standard value Wiring harness between C03 (female) (21), (31),
in normal state (32), (33) – JB54 – ground
Wiring harness between C03 (female) (1), (2),
(12), (22) – A03 (male) (2), (4)
GND circuit) Wiring harness between A03 (female) (2), (4) –
B28B
Wiring harness between battery relay terminal M
– B28B
Defective pump con- out troubleshooting.
4
troller 1 Between C03 (1), (2), (12), (22) – (21), (31), (32),
Voltage 20 – 30 V
(33)
20 PC2000-8
Circuit diagram related to pump controller 1 power supply
PC2000-8 21
Failure code [dA22KK] Pump 2 Solenoid Power Low Error 1

User code Failure code Pump 2 Solenoid Power Low Error
Trouble
E0E dA22KK (Pump controller 2 system)
Contents of
• Pump controller solenoid valve is below 20 V.
trouble
Action of
• Limits engine speed to upper limit of 1,400 rpm.
controller
• If the solenoid supply voltage drops radically, the swing speed of work equipment and machine
Problem that travel speed is substantially reduced.
appears on • Engine speed does not rise above 1,400 rpm.
machine • Swing brake cannot be released.
• The machine deviates during travel.
Related
• If [D110KB] is displayed, carry out troubleshooting for it first.
information

Defective circuit a If circuit breaker B25 or B28 is turned OFF, circuit probably has ground
1
breaker B25 or B28 fault etc. (See Cause 3.)
Wiring harness between CP06 (female) (2), (12),
Resistance Max. 1 z
(22) – JC17 and JB52
Disconnection in wiring Wiring harness between CP06 (female) (1), (11)
– JB49 – B28
ing or defective contact Wiring harness between battery relay terminal M
Resistance Max. 1 z
in connector) – B11
Possible Wiring harness between starting switch terminal
Resistance Max. 1 z
causes and BR – battery relay terminal BR
standard value Wiring harness between CP06 (female) (21),
(31), (32), (33) – ground
Wiring harness between CP06 (female) (2), (12),
(22) – JB17 and JB52
GND circuit) Wiring harness between CP06 (female) (1), (11)
– B28B
Wiring harness between battery relay terminal M
– B11
4
troller 2
Between CP06 (2), (12), (22) – (31), (32), (33) Voltage 20 – 30 V
22 PC2000-8
Electric diagram related to pump controller power supply
PC2000-8 23
Failure code [DA25KP] Pump 1 Sens Supply Vol Low Error 1

User code Failure code Pump 1 Sens Supply Vol Low Error
Trouble
E07 DA25KP (Pump controller 1 system)
Contents of
• Abnormal current flowed in pressure sensor power supply (5V) circuit.
trouble
• Turns output to power supply (5V) circuit OFF.
Action of
• If the trouble disappears over time, the output is restored but the failure code is held as is until the
controller
starting switch is turned on again.
• Signal of pressure sensor is not input normally.
Problem that
• Pressure sensor failure code is displayed at the same time.
appears on
• Travel and work equipment speeds are insufficient.
machine
• Fine controllability turns bad.
• State of the input voltage from the pressure sensor can be checked with monitoring function.
Related
(Code: 01128 PIF, 01129 PIR, 01130 P2F, 01131 P2R, 01133 RAD, 01135 O/C, pressure sensor
information
input voltage)

a Disconnect connector with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
VL1 – P1R pressure
P25 connector
sensor
VL2 – P2R pump pres-
P26 connector
sure sensor
Defective pressure
Disconnect sensors at VR1 – P1F pressure
1 sensor P32 connector
right in order. If no error sensor
code is displayed, that VR2 – P2F pressure
sensor is defective. P33 connector
sensor
Fan pump (O/C) pres-
P34 connector
sure sensor
Fan pump (RAD) pres-
P35 connector
sure sensor
causes and turning starting switch ON.
standard value Wiring harness between CP01 (female) (22) –
in normal state JB116 – P25 (female) (3) and chassis ground Resistance Min. 1 Mz
[VL1 – P1R pump pressure sensor system]
Wiring harness between CP01 (female) (22) –
JB116 – P26 (female) (3) and chassis ground Resistance Min. 1 Mz
[VL2 – P2R pump pressure sensor system]
Ground fault in wiring Wiring harness between CP01 (female) (22) –
harness JA116 – P32 (female) (3) and chassis ground Resistance Min. 1 Mz
2
(Short circuit with GND [VR1 – P1F pressure sensor system]
circuit) Wiring harness between CP01 (female) (22) –
[VR2 – P2F pressure sensor system]
[Fan pump (O/C) pressure sensor]
[Fan pump (RAD) pressure sensor system]
24 PC2000-8

standard value Defective pump con-
3
in normal state troller 1 CP01 Voltage
Between (22) – (21) 4.5 – 5.5 V
Circuit diagram related to pressure sensor power supply of pump controller 1
PC2000-8 25
Failure code [dA25KP] Pump 2 Sens Supply Vol Low Error 1

User code Failure code Pump 2 Sens Supply Vol Low Error
Trouble
— dA25KP (Pump controller 2 system)
Contents of
• Abnormal current flowed in pressure sensor power supply circuit.
trouble
• Stops output to the power supply circuit.
Action of
controller
Problem that • Failure code of the pressure sensor abnormality is displayed at the same time.
appears on • Work equipment and travel speed is low.
machine • Fine control performance is poor.
• State of the input voltage from the pressure sensor can be checked with monitoring function.
Related (Code: 07401 BOOM RAISE, 07501 BOOM LOWER, 07302 BUCKET CURL, 07303 BUCKET
information DUMP, 07601 ARM OUT, 07201 ARM IN, 09003 SWING LEFT, 09004 SWING RIGHT,
13901 AUTOMATIC LUBRICATION)

Boom raise pressure
P01 connector
sensor
Boom lower pressure
P02 connector
sensor
Bucket curling pres-
P03 connector
sure sensor
Defective pressure Disconnect device sug- Bucket dumping pres- P04 connector
1 sensor (internal short gested on the right. At sure sensor
circuit) this time, if failure code Arm OUT pressure sen-
P05 connector
is not indicated, the sor
device is defective. Arm IN pressure sensor P06 connector
Swing left pressure
P07 connector
sensor
Swing right pressure
P08 connector
sensor
Possible Automatic lubrication
P48 connector
causes and pressure sensor
Between wiring harness of CP04 (female) (22) –
GND circuit) Between wiring harness of CP04 (female) (22) –
26 PC2000-8

standard value Defective pump con-
3
troller 2 CP04 Voltage
in normal state
Between (22) and (21) 4.5 – 5.5 V
PC2000-8 27
Failure code [DA26KP] 5V Sensor 2 Power Abnormality 1

User code Failure code 5V Sensor 2 Power Abnormality
Trouble
E07 DA26KP (Engine controller 1 system)
Contents of
• Abnormal current flowed in pressure sensor power supply circuit.
trouble
• Stops output to the power supply circuit.
Action of
controller
Problem that
appears on • Differential sensor is not working, disabling pump control.
machine
Related • Input state of pressure sensor can be checked with monitoring function.
information (Codes: 13808 VR1, 13809 VL1, 13810 VR2, 13811 VL2 and J/S differential pressure)

a Disconnect connector with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
(VR1 and P1F) J/S dif-
ferential pressure sen- P36 connector
sor
(VL1 and P1R) J/S dif-
Defective J/S differen- Disconnect device sug-
1 tial pressure sensor gested on the right. At sor
(internal short circuit) this time, if failure code
is not indicated, the (VR2 and P2F) J/S dif-
device is defective.
sor
(VL2 and P2R) J/S dif-
Possible ferential pressure sen- P28 connector
causes and sor
standard value
in normal state
GND circuit)
3
troller 1 CP03 Voltage
Between (34) and CP01 (21) 4.5 – 5.5 V
28 PC2000-8
PC2000-8 29
Failure code [DA29KQ] Pump 1 Model Select Abnormality 1

User code Failure code Pump 1 Model Select Abnormality
Trouble
— DA29KQ (Pump controller 1 system)
• Model code signal for other model than registered in the controller is input.
Contents of
• When key is ON, a state continued for over 5 sec where model selection input was for other model
trouble
than registered or the model selection input state changed while operating.
• If it is abnormal upon key ON, the controller performs as pump controller 1.
Action of
• When abnormality occurs after key is turned OFF, model information at key-ON time will be
controller
retained.
Problem that
• It does not work when optional model is selected.
appears on
• If the pump controller is misidentified as 2nd controller, it cannot be controlled.
machine
Related • Input state of model selection code can be checked with monitoring function.
information (Monitoring code: 00200 name of selected model, 02209 switch input 6, model selection 1: ON)

harness (Disconnec-
1
tion or defective con- Wiring harness between CP02 (female) (37) – Min. 1 Mz
Possible tact in connector) JC8 – A03 (19) – JB54 – A24 and chassis Resistance
Max. 1 z
causes and ground
standard value a Prepare with starting switch OFF, then turn starting switch ON or start
in normal state engine and carry out troubleshooting in each case.
Defective pump con- CP02 Voltage
2
troller 1 Between (7) or (17) and chassis
20 – 30 V
ground
Between (37) and chassis ground Max. 1 V
Note:
Machine select 1: CP02 (37), Machine select 2: The input voltage depends the specification except CP02
(27).
(CP02 (37) when normal: Input ON "Voltage 1 V maximum", CP02 (27): Input OFF "Voltage 5 V minimum")
30 PC2000-8
Circuit diagram related to model select (pump controller 1)
PC2000-8 31
Failure code [dA29KQ] Pump 2 Model Select Abnormality 1

User code Failure code Pump 2 Model Select Abnormality
Trouble
— dA29KQ (Pump controller 2 system)
• Model code signal for other model than registered in the controller is input.
Contents of
• When key is ON, a state continued for over 5 sec where model selection input was for other model
trouble
than registered or the model selection input state changed while operating.
• If it is abnormal upon key ON, the controller performs as pump controller 1.
Action of
• When abnormality occurs after key is turned OFF, model information at key-ON time will be
controller
retained.
Problem that
• It does not work when optional model is selected.
appears on
• If the pump controller is misidentified as 1st controller, the ON/OFF valve cannot be controlled.
machine
Related • Input state of model selection can be checked with monitoring function.
information (Monitoring code: 02205 switch input 2, model selection 2: ON)

harness (Disconnec-
1
tion or defective con- Wiring harness between CP05 (female) (27) –
Possible tact in connector) JC13 – A03 (26) – JB56 – A24 (1) and chassis Resistance Max. 1 z
causes and ground
standard value a Prepare with starting switch OFF, then turn starting switch ON or start
in normal state engine and carry out troubleshooting in each case.
2
troller 2 Between (7) or (17) and chassis
20 – 30 V
ground
Between (37) and chassis ground Max. 1 V
Note:
Machine select 1: CP05 (37), Machine select 2: The input voltage depends the specification except CP05
(27).
(CP05 (37) when normal: Input OFF "Voltage 5 V minimum", CP05 (27): Input ON "Voltage 1 V maximum")
32 PC2000-8
Circuit diagram related to model select (pump controller 2)
PC2000-8 33
Failure code [DA2RMC] CAN Discon (Pump 1 Con Detected) 1

User code Failure code CAN Discon (Pump 1 Con Detected)
Trouble
E0E DA2RMC (Pump controller 1, 2 system)
Contents of • Pump controller 1 detected communication error in CAN communication circuit between machine
trouble monitor, pump controller 2 and engine controller.
Action of
• The fan speed is set to the maximum.
controller
• Engine speed cannot be controlled.
Problem that
• Overheated water temperature judgment is failed.
appears on
• The fan speed is set to the maximum, while work equipment, swing and machine travel speed are
machine
decreased.
Related
information

Disconnection in wiring Wiring harness between CM02 (female) (10) –
harness (Disconnec- CE02, CE05 (female) (47) – CP02, CP05 Resistance Max. 1 z
1
tion or defective con- (female) (22) – VH04 (female) (12)
tact in connector) Wiring harness between CM02 (female) (8), (9) –
CE02 – CE05 (female) (46) – CP02, CP05 Resistance Max. 1 z
(female) (32) – VH04 (female) (4), (6), (14)
CE02, CE05 (female) (47) – CP02, CP05
(female) (22) – VH04 (female) (12), and chassis
ground
GND circuit)
Wiring harness between CM02 (female) (8), (9) –
CE02, CE05 (female) (46) – CP02, CP05
(female) (32) – VH04 (female) (4), (6), (14), and
causes and
chassis ground
standard value
in normal state
CE02, CE05 (female) (47) – CP02, CP05
Hot short in wiring har- Voltage Max. 1 V
ground
V circuit)
CE02, CE05 (female) (46) – CP02, CP05
Voltage Max. 1 V
chassis ground
Defective CAN termi- turning starting switch ON.
4
nal resistance K01 (male), K03 (male) Resistance
Between (A) and (B) 120 z ± 10 %
Defective machine
If causes 1 to 4 are not detected, machine monitor, engine controller, or
monitor, engine con-
5 pump controller may be defective. (Troubleshooting cannot be carried out
troller, or pump control-
since trouble is in the system.)
ler 1 and 2
34 PC2000-8
Circuit diagram related to CAN communication (pump controller 1)
PC2000-8 35
Failure code [dA2RMC] CAN Discon (Pump 2 Con Detected) 1

User code Failure code CAN Discon (Pump 2 Con Detected)
Trouble
E0E dA2RMC (Pump controller 1, 2 system)
Contents of • Pump controller 2 detected communication error in CAN communication circuit between machine
trouble monitor, pump controller 1 and engine controller.
Action of
• None in particular (Provides the error display alone)
controller
Problem that
appears on • Control data cannot be sent.
machine
Related
information

CE02, CE05 (female) (47) – CP02, CP05 Resistance Max. 1 z
harness (Disconnec-
1 (female) (22) – VH04 (female) (12)
tion or defective con-
CE02, CE05 (female) (46) – CP02, CP05
Resistance Max. 1 z
chassis ground
CE02, CE05 (female) (47) – CP02, CP05
(female) (22) – VH04 (female) (12) and chassis
ground
GND circuit)
Possible Wiring harness between CM02 (female) (8), (9) –
causes and CE02, CE05 (female) (46) – CP02, CP05
standard value (female) (32) – VH04 (female) (4), (6), (14), and
in normal state chassis ground
CE02, CE05 (female) (47) – CP02, CP05
ground
V circuit)
CE02, CE05 (female) (46) – CP02, CP05
Voltage Max. 1 V
chassis ground
4
nal resistance K03, K01 (male) Resistance
Between (A) and (B) 120 z ± 10 %
Defective pump con- If causes 1 – 4 are not detected, engine controller may be defective.
5
troller 1 and 2 (Troubleshooting cannot be carried out since trouble is in system.)
36 PC2000-8
Circuit diagram related to CAN communication (pump controller 2)
PC2000-8 37
Failure code [DA2TMC] Pump Comm. ECM Child Abnormality 1

User code Failure code Pump Comm. ECM Child Abnormality
Trouble
— DA2TMC (Engine controller system)
Contents of • There is error in KOMNET communication circuits with pump controller 1 and engine controller
trouble child.
Action of
controller
Problem that
appears on • Error from the engine Child system cannot be detected.
machine
Related
information

1
(female) (32) – VH04 female) (4), (6), (14)
CE02, CE05 (female) (47) – CP02, CP05
ground
GND circuit)
CE02, CE05 (female) (46) – CP02, CP05
causes and chassis ground
standard value
CE02, CE05 (female) (47) – CP02, CP05
ground
V circuit)
CE02, CE05 (female) (46) – CP02, CP05
Voltage Max. 1 V
chassis ground
4
nal resistance K01, K03 K03 Resistance
Between (A) and (B) Between (A) and (B) 120 z ± 10 %
Defective machine
monitor, engine con- If causes 1 – 4 are not detected, engine controller may be defective.
5
troller or pump control- (Troubleshooting cannot be carried out since trouble is in system.)
ler 1
38 PC2000-8
Circuit diagram related to KOMNET communication
PC2000-8 39
Failure code [DBB0KK] VHMS Source Voltage Error (or change of

User code Failure code VHMS Source Voltage Error
Trouble
— DBB0KK (VHMS controller system)
Contents of
• While engine is running, VHMS controller switch supply voltage is below 19.5 V.
trouble
Action of
controller
Problem that
appears on • The system may not work normally.
machine

Defective circuit If circuit breaker is shut down, the circuit probably has a ground fault. (See
1
breaker Cause 3)
harness (Disconnec- Wiring harness between CV01 (female) (8), (9)
tion or defective con- and battery relay (M) terminal
Possible tact in connector) Between CV01 (female) (19), (20) and chassis
ground
standard value
Between wiring harness of CV01 (female) (8), (9)
– battery relay (M) terminal and chassis ground
a Prepare with starting switch OFF, then turn starting switch START and
Defective VHMS carry out troubleshooting.
4
controller CV01 Voltage
Between (8), (9) and (19), (20) 20 – 30 V
40 PC2000-8
Circuit diagram related to VHMS controller
PC2000-8 41
Failure code [DBB0KQ] VHMS Connector Mismatch (or change of

VHMS-LED display from nF to 11) 1
User code Failure code Defective VHMS controller connection
Trouble
— DBB0KQ (VHMS controller system)
Contents of
• Improper connection of VHMS controller connectors CV02A, CV02B, CV03A and CV03B
trouble
Action of
controller
Problem that
appears on • Data being downloaded to PC is not displayed normally.
machine
information • VHMS controller 7-segment LED display: nF o 11 (codes are displayed by 2 digits)

Check the VHMS controller connectors CV02A and CV03A or CV02B and
Improper connector
1 CV03B for improper connection.
connection
a For the connecting positions of the connectors to the VHMS controller,
refer to Testing and adjusting, Part 4, "Preparation work for trouble-
shooting of electrical system."
Possible Disconnection in wiring Wiring harness between CV02A (female) (9) –
causes and harness (Disconnec- JB67 – JB18 – A24 – Battery (–) terminal and Resistance Max. 1 z
2
standard value tion or defective chassis ground (power container)
in normal state contact in connector) Wiring harness between CV02B (female) (12) –
JB67 – JB18 – A24 – Battery (–) terminal and Resistance Max. 1 z
chassis ground (power container)
Between CV02A (9) – (13) Voltage Max. 1 V
Defective VHMS Between CV02B (12) – (9) Voltage Max. 1 V
3
controller Between CV03A (9) – (13) Voltage 20 – 30 V
Between CV03B (12) – (9) Voltage 20 – 30 V
If the above 1 and 2 are normal, VHMS controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
42 PC2000-8
Circuit diagram related to VHMS controller
PC2000-8 43
Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMS-
User code Failure code VHMS 5V source sys Error
Trouble
— DBB5KP (VHMS controller system)
Contents of
• The sensor supply voltage is out of the normal range (4.5 – 5.5 V).
trouble
Action of
controller
Problem that
appears on • The sensor value may not be displayed normally.
machine

Disconnection in wiring Wiring harness between CV01 (female) (5) – Resistance Max. 1 z
harness (Disconnec- ENBP (female) (B)
1
tion or defective con- Wiring harness between CV02A (female) (13) –
Resistance Max. 1 z
tact in connector) ENBP (female) (A)
Wiring harness between CV02A (female) (18) –
Resistance Max. 1 z
ENBP (female) (C)
causes and
standard value
Between wiring harness of CV01 (female) (5) –
in normal state Ground fault in wiring Resistance Min. 1 Mz
ENBP (female) (B) and chassis ground
ENBP (female) (A) and chassis ground
ENBP (female) (C) and chassis ground
Defective VHMS out troubleshooting.
3
controller CV01, CV02A Voltage
Between CV01 (5) and CV02A (13) 4.5 – 5.5 V
44 PC2000-8
Circuit diagram related to VHMS controller sensor 5V power source
PC2000-8 45
Failure code [DBB6KP] VHMS 24V source sys Error (or change of
User code Failure code VHMS 24V source sys Error
Trouble
— DBB6KP (VHMS controller system)
Contents of
• The sensor supply voltage is out of the normal range (20 – 30 V).
trouble
Action of
controller
Problem that
appears on • The sensor value may not be displayed normally.
machine

Wiring harness between CV01 (female) (2) –
Resistance Max. 1 z
Disconnection in wiring P41A (female) (A)
harness (Disconnec- Wiring harness between CV01 (female) (2) –
tion or defective con- P41B (female) (A)
tact in connector) Wiring harness between CV01 (female) (2) –
Resistance Max. 1 z
P41C (female) (A)
Wiring harness between CV01 (female) (2) –
Resistance Max. 1 z
P41D (female) (A)
causes and
standard value
P41A (female) (A) and chassis ground
P41B (female) (A) and chassis ground
GND circuit)
P41C (female) (A) and chassis ground
P41D (female) (A) and chassis ground
Defective VHMS out troubleshooting.
3
controller CV01, CV02A Voltage
Between CV01 (2) and CV02 (13) 20 – 30 V
46 PC2000-8
Circuit diagram related to VHMS controller sensor 24V power source
PC2000-8 47
Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED

User code Failure code KOM-NET/c error
Trouble
— DBBQKR (VHMS controller system)
Contents of • Communication (CANNET) information from engine controller, pump controller and machine moni-
trouble tor cannot be received.
Action of
• The state of error occurred is held.
controller
Problem that
appears on • VHMS function fails to collect information from respective controllers.
machine
Related • VHMS controller 7-segment LED display: n8 o 02 (codes are displayed by 2 digits)
information • If failure codes [CA1633], [DA2RMC] and [DAFRMC] are indicated, carry out troubleshooting for
those codes first.

1
(female) (32) – VH04 (female) (4), (6), (14)
CE02, CE05 (female) (47) – CP02, CP05
ground
GND circuit)
Possible CE02, CE05 (female) (46) – CP02, CP05
causes and (female) (32) – VH04 (female) (4), (6), (14), and
standard value chassis ground
CE02, CE05 (female) (47) – CP02, CP05
ground
V circuit)
Between wiring harness between CM02 (female)
(8), (9) – CE02, CE05 (female) (46) – CP02,
Voltage Max. 1 V
CP05 (female) (32) – VH04 (female) (4), (6),
(14), and chassis ground
1) Turn the starting switch OFF.
2) Replace VHMS controller
3) Turn starting switch ON.
Defective VHMS
4 Defective VHMS
controller Normal
Communication controller
normal? VHMS controller is
Abnormal
normal
48 PC2000-8
Circuit diagram related to CAN communication
PC2000-8 49
Failure code [DGE5KX] Ambient Air Temp Sensor Failure (or change of
User code Failure code Ambient Air Temp Sensor Failure
Trouble
— DGE5KX (VHMS controller system)
Contents of
• Input signal from the sensor is below 0.3 V.
trouble
Action of
controller
Problem that
appears on •
machine

Defective atmospheric turning starting switch ON.
temperature sensor
1 Atmospheric
(Internal disconnec- P29 (male) Resistance
temperature
tion or short circuit)
Between (1) and (2) 20°C 4 – 6 kz
harness (Disconnec- Wiring harness between CV02A (female) (10) –
tion or defective con- P29 (female) (1)
tact in connector) Wiring harness between CV02A (female) (12) –
Resistance Max. 1 z
P29 (female) (2)
Possible out troubleshooting.
causes and Ground fault in wiring
standard value Between wiring harness of CV02A (female) (10)
– P29 (female) (1) and chassis ground
in normal state GND circuit)
Between wiring harness of CV02A (female) (12)
4 ness (Contact with 24 Voltage Max. 1 V
V circuit)
Voltage Max. 1 V
Defective VHMS
5 Atmospheric
controller CV02A Resistance
temperature
Between (10) and (12) 20°C 4 – 6 kz
50 PC2000-8
Circuit diagram related to ambient air temperature sensor
PC2000-8 51
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C 1

User code Failure code Hydr. Oil Temp. Sensor S/C
Trouble
— DGH2KB (Pump controller 2 system)
Contents of
• The input voltage from the temperature sensor remained at 0.3 V or below for 5 seconds or more.
trouble
Action of
• The fan speed is set to the maximum.
controller
Problem that
appears on • If the machine is used as it is, the hydraulic equipment may be damaged.
machine
Related • Input from the hydraulic oil temperature sensor can be checked in the monitoring function. (Code
information No. 04401: Hydraulic oil temperature, 04403: Hydraulic oil temperature sensor voltage

Hydraulic oil tempera- Hydraulic oil tempera-
ture sensor defective P22 (male) Resistance
1 ture
(Internal short-circuit-
ing) Between (1) – (2) 90 – 3.5 kz
Between (1) – chassis 10 – 100°C
Min. 1 Mz
ground
Possible
causes and Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without
ing harness turning starting switch ON.
standard value 2
in normal state (Contact with ground- Between wiring harness between CP04 (female)
ing circuit) Resistance Min. 1 Mz
(4) – P22 (female) (2) and chassis ground
Hydraulic oil tempera-
Pump controller 2 CP04 (female) Resistance
3 ture
defective
Between (4) – (9) 90 – 3.5 kz
Between (4) – 10 – 100°C
Min. 1 Mz
chassis ground
52 PC2000-8
PC2000-8 53
Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMS-
User code Failure code PTO Temp Sensor Failure
Trouble
— DGT3KZ (VHMS controller system)
Contents of
• Signal voltage from PTO oil temperature sensor is below 0.3V.
trouble
Action of
controller
Problem that
appears on • The snapshot data downloaded to the PC is not displayed normally.
machine
Related
information
• PTO oil temperature can be checked by downloading data to PC after the snapshot.

Defective PTO oil tem- turning starting switch ON.
perature sensor (inter-
1 P19 (male) Oil temperature Resistance
25°C 46 – 59 kz
short circuit) Between (1) and (2)
100°C 3.6 – 4.0 kz
harness (Disconnec- Wiring harness between CV02A (female) (2) –
tion or defective con- P19 (female) (1)
tact in connector) Wiring harness between CV02A (female) (12) –
Resistance Max. 1 z
P19 (female) (2)
Possible
causes and Ground fault in wiring
standard value 3 harness (Contact with
in normal state GND circuit) Between wiring harness of CV02A (female) (2) –
a Prepare with starting switch OFF, then turn it ON and carry out trouble-
shooting.
V circuit) Between wiring harness of CV02A (female) (2) –
Voltage Max. 5 V
CV02A (female) Oil temperature Resistance
Defective VHMS
5 25°C 46 – 59 kz
controller Between (2) and (12)
100°C 3.6 – 4.0 kz
— Min. 1 Mz
sis ground
54 PC2000-8
Circuit diagram related to PTO oil temperature sensor
PC2000-8 55
SEN02099-00

© 2006 KOMATSU
All Rights Reserved
56
SEN02100-00
PC2000-8

PC2000-8 20001 and up
Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure
Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure
Failure code [DGT5KB] Exhaust Temp. Sensor LBF Failure
(or change of VHMS-LED display from n3 to 11) ....................................................................... 8
Failure code [dGT5KB] Exhaust Temp. Sensor LBR Failure
Failure code [DGT6KA] Exhaust Temp. Sensor RBF Failure
(or change of VHMS-LED display from n3 to 24).................................................................... 12
Failure code [dGT6KA] Exhaust Temp. Sensor RBR Failure
Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure
PC2000-8 1
Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure

Failure code [DH25KX] VR1/P1F J/S Dif Press Sensor Abnormality................................................. 20
Failure code [DH26KX] VL1/P1R J/S Dif Press Sensor Abnormality ................................................. 22
Failure code [DH27KX] VR2/P2F J/S Dif Press Sensor Abnormality................................................. 24
Failure code [DH28KX] VL2/P2R J/S Dif Press Sensor Abnormality ................................................. 26
Failure code [DHE5KB] Blowby Pres. Sensor Failure
Failure code [DHE5KY] Blowby Pres. Sensor Failure
Failure code [DHH2KA] Hydraulic oil filter Sensor Failure
Failure code [DHPEKX] VR1/P1F Pump P. Sensor Abnormality ....................................................... 34
Failure code [DHPFKX] VL1/P1R Pump P. Sensor Abnormality ........................................................ 36
Failure code [DHPGKX] VR2/P2F Pump P. Sensor Abnormality ....................................................... 38
Failure code [DHPHKX] VL2/P2R Pump P. Sensor Abnormality ....................................................... 40
Failure code [DHPSKX] Auto Grease Press Sensor Abnormality ...................................................... 42
Failure code [DHPTKX] Fan(RAD) Pump P. Sensor Open Circuit ..................................................... 44
Failure code [DHPUKX] Fan(O/C) Pump P. Sensor Open Circuit ...................................................... 46
Failure code [DHS3KX] Arm Dig PPC Press Sensor Abnormality ..................................................... 48
Failure code [DHS4KX] Bucket Curl PPC Press Sensor Abnormality................................................ 50
Failure code [DHS8KX] Boom Raise PPC Press Sensor Abnormality............................................... 52
Failure code [DHS9KX] Boom Lower PPC Press Sensor Abnormality .............................................. 54
Failure code [DHSAKX] Swing Right PPC Press Sensor Abnormality............................................... 56
Failure code [DHSBKX] Swing Left PPC Press Sensor Abnormality ................................................. 58
Failure code [DHSCKX] Arm Dump PPC Press Sensor Abnormality ................................................ 60
Failure code [DHSDKX] Bucket Dump PPC Press Sensor Abnormality ............................................ 62
2 PC2000-8

Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure (or change of
User code Failure code Exhaust Temp. Sensor LBF Failure
Trouble
— DGT5KA (VHMS controller system)
Contents of
• Exhaust gas temperature sensor (LB/F) signal voltage is below 0.5 V.
trouble
Action of
controller
Problem that
machine
Related
information
• Exhaust gas temperature can be checked by downloading data to PC after the snapshot.

Defective sensor 24 V If failure code [DBB6KP] is displayed, carry out the troubleshooting first as
1
power supply system stated.
Defective exhaust gas
bleshooting.
temperature sensor
2 Switch between the rear and front exhaust gas
(LB/F) (Internal discon- VH16 connector
nection) temperature sensor connectors. If no error code
VH17 connector
is displayed, that sensor is normal.
Exhaust gas
P41A Voltage
Defective amplifier for temperature
exhaust gas tempera- (A) – (C) All temperature range 20 – 30 V
3
ture sensor (LB/F) 20°C Approx. 0.9 – 1.2 V
(Internal defect) (B) – (C)
500°C Approx. 2.6 – 3.5 V
Amplifier voltage is measured with wiring harness connected. Accordingly,
if voltage is abnormal, check wiring harness or controller, too, for another
Possible cause of trouble, and then judge.
in normal state Wiring harness between P42A (male) (1) – VH16
Resistance Max. 1 z
Disconnection in wiring (female) (1)
harness (Disconnec- Wiring harness between P42A (male) (2) – VH16
tion or defective con- (female) (2)
Resistance Max. 1 z
P41A (female) (A)
Resistance Max. 1 z
P41A (female) (B)
Between wiring harness CV02A (female) (5) –
P41A (female) (B) and chassis ground
Defective VHMS Exhaust gas
6 CV02A Voltage
20°C Approx. 0.9 – 1.2 V
Between (5) and (13)
500°C Approx. 2.6 – 3.5 V
4 PC2000-8
Circuit diagram related to exhaust temperature sensor
PC2000-8 5
Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure (or change of
User code Failure code Exhaust Temp. Sensor LBR Failure
Trouble
— dGT5KA (VHMS controller system)
Contents of
• Exhaust gas temperature sensor (LB/R) signal voltage is below 0.5 V.
trouble
Action of
controller
Problem that
machine
Related
information

1
bleshooting.
temperature sensor
(LB/R) (Internal dis- VH16 connector
connection) temperature sensor connectors. If no error code
VH17 connector
Exhaust gas
P41B Voltage
3
ture sensor (LB/R) 20°C Approx. 0.9 – 1.2 V
500°C Approx. 2.6 – 3.5 V
in normal state Wiring harness between P42B (male) (1) – VH17
Resistance Max. 1 z
harness (Disconnec- Wiring harness between P42B (male) (2) – VH17
Resistance Max. 1 z
P41B (female) (A)
Resistance Max. 1 z
P41B (female) (B)
P41B (female) (B) and chassis ground
6 CV02A Voltage
20°C Approx. 0.9 – 1.2 V
500°C Approx. 2.6 – 3.5 V
6 PC2000-8
PC2000-8 7
Failure code [DGT5KB] Exhaust Temp. Sensor LBF Failure (or change of
User code Failure code Exhaust Temp. Sensor LBF Failure
Trouble
— DGT5KB (VHMS controller system)
Contents of
• Exhaust gas temperature sensor (LB/F) signal voltage is above 4.9 V.
trouble
Action of
controller
Problem that
machine
Related
information

1
bleshooting.
temperature sensor
(LB/F) (Internal discon- VH16 connector
nection) temperature sensor connectors. If no error code
VH17 connector
Exhaust gas
P41A Voltage
3
ture sensor (LB/F) 20°C Approx. 0.9 – 1.2 V
Possible 500°C Approx. 2.6 – 3.5 V
causes and Amplifier voltage is measured with wiring harness connected. Accordingly,
standard value if voltage is abnormal, check wiring harness or controller, too, for another
in normal state cause of trouble, and then judge.
Between wiring harness P42A (male) (1) – VH16
P41A (female) (B) and chassis ground
6 CV02A Voltage
20°C Approx. 0.9 – 1.2 V
500°C Approx. 2.6 – 3.5 V
8 PC2000-8
PC2000-8 9
Failure code [dGT5KB] Exhaust Temp. Sensor LBR Failure (or change of
User code Failure code Exhaust Temp. Sensor LBR Failure
Trouble
— dGT5KB (VHMS controller system)
Contents of
• Exhaust gas temperature sensor (LB/R) signal voltage is above 4.9 V.
trouble
Action of
controller
Problem that
machine
Related
information

1
bleshooting.
temperature sensor
(LB/R) (Internal dis- VH16 connector
VH17 connector
Exhaust gas
P41B Voltage
3
ture sensor (LB/R) 20°C Approx. 0.9 – 1.2 V
Between wiring harness P42B (male) (1) – VH17
P41B (female) (B) and chassis ground
6 CV02A Voltage
20°C Approx. 0.9 – 1.2 V
500°C Approx. 2.6 – 3.5 V
10 PC2000-8
PC2000-8 11
Failure code [DGT6KA] Exhaust Temp. Sensor RBF Failure (or change of
User code Failure code Exhaust Temp. Sensor RBF Failure
Trouble
— DGT6KA (VHMS controller system)
Contents of
• Exhaust gas temperature sensor (RB/F) signal voltage is below 0.5 V.
trouble
Action of
controller
Problem that
machine
Related
information

1
bleshooting.
temperature sensor
(RB/F) (Internal dis- VH18 connector
VH19 connector
Exhaust gas
P41C Voltage
3
ture sensor (RB/F) 20°C Approx. 0.9 – 1.2 V
500°C Approx. 2.6 – 3.5 V
in normal state Wiring harness between P42C (male) (1) – VH18
Resistance Max. 1 z
harness (Disconnec- Wiring harness between P42C (male) (2) – VH18
Resistance Max. 1 z
P41C (female) (A)
Resistance Max. 1 z
P41C (female) (B)
P41C (female) (B)and chassis ground
6 CV02A Voltage
20°C Approx. 0.9 – 1.2 V
500°C Approx. 2.6 – 3.5 V
12 PC2000-8
PC2000-8 13
Failure code [dGT6KA] Exhaust Temp. Sensor RBR Failure (or change of
User code Failure code Exhaust Temp. Sensor RBR Failure
Trouble
— dGT6KA (VHMS controller system)
Contents of
• Exhaust gas temperature sensor (RB/R) signal voltage is below 0.5 V.
trouble
Action of
controller
Problem that
machine
Related
information

1
bleshooting.
temperature sensor
(RB/R) (Internal dis- VH18 connector
VH19 connector
Exhaust gas
P41D Voltage
3
ture sensor (RB/R) 20°C Approx. 0.9 – 1.2 V
500°C Approx. 2.6 – 3.5 V
in normal state Wiring harness between P42D (male) (1) – VH19
Resistance Max. 1 z
harness (Disconnec- Wiring harness between P42D (male) (2) – VH19
Resistance Max. 1 z
P41D (female) (A)
Resistance Max. 1 z
P41D (female) (B)
P41D (female) (B) and chassis ground
6 CV02A Voltage
20°C Approx. 0.9 – 1.2 V
500°C Approx. 2.6 – 3.5 V
14 PC2000-8
PC2000-8 15
Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure (or change of
User code Failure code Exhaust Temp. Sensor RBF Failure
Trouble
— DGT6KB (VHMS controller system)
Contents of
• Exhaust gas temperature sensor (RB/F) signal voltage is above 4.9 V.
trouble
Action of
controller
Problem that
machine
Related
information

1
bleshooting.
temperature sensor
(RB/F) (Internal dis- VH18 connector
VH19 connector
Exhaust gas
P41C Voltage
3
ture sensor (RB/F) 20°C Approx. 0.9 – 1.2 V
P41C (female) (B) and chassis ground
P41C (female) (B) and chassis ground
6 CV02A Voltage
20°C Approx. 0.9 – 1.2 V
500°C Approx. 2.6 – 3.5 V
16 PC2000-8
PC2000-8 17
Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure (or change of
User code Failure code Exhaust Temp. Sensor RBR Failure
Trouble
— dGT6KB (VHMS controller system)
Contents of
• Exhaust gas temperature sensor (RB/R) signal voltage is above 4.9 V.
trouble
Action of
controller
Problem that
machine
Related
information

1
bleshooting.
temperature sensor
(RB/R) (Internal dis- VH18 connector
VH19 connector
Exhaust gas
P41D Voltage
3
ture sensor (RB/R) 20°C Approx. 0.9 – 1.2 V
Between wiring harness P42D (male) (1) – VH19
P41D (female) (B) and chassis ground
6 CV02A Voltage
20°C Approx. 0.9 – 1.2 V
500°C Approx. 2.6 – 3.5 V
18 PC2000-8
PC2000-8 19
Failure code [DH25KX] VR1/P1F J/S Dif Press Sensor Abnormality 1

User code Failure code VR1/P1F J/S Dif Press Sensor Abnormality
Trouble
E07 DH25KX (Pump controller 1 system)
Contents of
• Pressure sensor output voltage is below 0.3 V or above 4.42 V.
trouble
Action of
• Restricts the pump control (NC control) function.
controller
Problem that
appears on • Part of the pump control (NC control) is disabled.
machine
• Input from the J/S differential pressure sensor can be checked with monitoring function.
Related
(Code: 13804 VR1 J/S differential pressure, Code: 13808 VR1 J/S differential pressure sensor volt-
information
age)

Defective 5 V sensor If failure code [DA26KP] is also indicated, carry out troubleshooting for it
1
Defective VR1-P1F J/S out troubleshooting.
differential pressure P36 Measurement condition Voltage
2 sensor (Internal dis-
Between (1) and (2) Engine stopped 4.5 – 5.5 V
connection or short cir-
cuit) Between (3) and (2) Engine stopped 0.5 – 1.5 V
Disconnection in wiring Wiring harness between CP01 (female) (8) –
Resistance Max. 1 z
harness (Disconnec- P36 (female) (1)
3
tact in connector) P36 (female) (2)
causes and
Resistance Max. 1 z
in normal state P36 (female) (3)
Between wiring harness CP01 (female) (8) – P36
GND circuit)
Between wiring harness CP03 (female) (34) –
V circuit)
Voltage Max. 6 V
Defective pump If causes 1 – 5 are not detected, pump controller may be defective.
6
controller 1 (Troubleshooting cannot be carried out since trouble is in system.)
20 PC2000-8
Circuit diagram related to VR1/P1F joystick differential sensor
PC2000-8 21
Failure code [DH26KX] VL1/P1R J/S Dif Press Sensor Abnormality 1

User code Failure code VL1/P1R J/S Dif Press Sensor Abnormality
Trouble
Contents of
trouble
Action of
controller
Problem that
machine
Related
(Code: 13805 VL1 J/S differential pressure, Code: 13809 VL1 J/S differential pressure sensor volt-
information
age)

1
Defective VL1-P1R J/S out troubleshooting.
Resistance Max. 1 z
3
causes and
Resistance Max. 1 z
GND circuit)
V circuit)
Voltage Max. 6 V
6
22 PC2000-8
Circuit diagram related to VL1/P1R joystick differential sensor
PC2000-8 23
Failure code [DH27KX] VR2/P2F J/S Dif Press Sensor Abnormality 1

User code Failure code VR2/P2F J/S Dif Press Sensor Abnormality
Trouble
Contents of
trouble
Action of
controller
Problem that
machine
Related
(Code: 13806 VR2 J/S differential pressure, Code: 13810 VR2 J/S differential pressure sensor volt-
information
age)

1
Defective VR2/P2F J/S out troubleshooting.
Resistance Max. 1 z
3
causes and
Resistance Max. 1 z
GND circuit)
Between wiring harness CP03 (female) (34) and
V circuit)
Voltage Max. 6 V
6
24 PC2000-8
Circuit diagram related to VR2/P2F joystick differential sensor
PC2000-8 25
Failure code [DH28KX] VL2/P2R J/S Dif Press Sensor Abnormality 1

User code Failure code VL2/P2R J/S Dif Press Sensor Abnormality
Trouble
Contents of
trouble
Action of
controller
Problem that
machine
Related
(Code: 13807 VL2 J/S differential pressure, Code: 13811 VL2 J/S differential pressure sensor volt-
information
age)

1
Defective VL2-P2R J/S out troubleshooting.
Resistance Max. 1 z
3
causes and
Resistance Max. 1 z
GND circuit)
V circuit)
Voltage Max. 6 V
6
26 PC2000-8
Circuit diagram related to VL2/P2R joystick differential sensor
PC2000-8 27
Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of

User code Failure code Blowby Pres. Sensor Failure
Trouble
— DHE5KB (VHMS controller system)
Contents of
• The signal voltage of the blow-by pressure sensor is below 0.1 V.
trouble
Action of
controller
Problem that
appears on • The snap shot data downloaded to a personal computer are not displayed normally.
machine
• The error codes of the VHMS system are not recorded in the failure history of the machine monitor.
Related • The 7-segment LED of the VHMS controller displays n3 o 32 (displays the code 2 characters by 2).
information • The blow-by pressure can be checked by downloading the data to a personal computer after per-
forming the snap shot operation.

Sensor 5-V power
1 If error code [DBB5KP] is displayed, perform troubleshooting for it first.
supply defective
VH08 Voltage
Blow-by pressure sen-
Between (B) and (A) 4.5 – 5.5 V
2 sor defective (Internal
defect) Between (C) and (A) 0.3 – 0.7 V
The voltage of the pressure sensor is measured with the wiring harness
connected. Accordingly, if the voltage is abnormal, check the wiring har-
ness and controller for another cause of the trouble, and then judge.
Blow-by pressure
Referring to TESTING AND ADJUSTING, check the sensor for sticking oil,
3 sensor defective
dust, water, etc. and clean it.
(External defect)
Possible
Blow-by pressure
causes and Referring to TESTING AND ADJUSTING, check the sensor for defective
4 sensor defective
standard value installation and repair it.
(Installation defective)
in normal state
Disconnection of wiring turning starting switch ON.
harness
Wiring harness between CV01 (female) (5) and Resistance
5 (Disconnection or Max. 1 z
P43 (female) (B) value
defective contact with
connector) Wiring harness between CV02A (female) (18) Resistance
Max. 1 z
and P43 (female) (C) value
6
(Contact with ground- Between wiring harness between CV02A Resistance
ing (GND) circuit) Min. 1 Mz
(female) (18) and P43 (female) (C) value
VHMS controller out troubleshooting.
7
defective CV02A Voltage
Between (18) and (13) 0.3 – 0.7 V
28 PC2000-8
Circuit diagram related to blow-by pressure sensor
PC2000-8 29
Failure code [DHE5KY] Blowby Pres. Sensor Failure (or change of

User code Failure code Blowby Pres. Sensor Failure
Trouble
— DHE5KY (VHMS controller system)
Contents of
• The signal voltage of the blow-by pressure sensor is above 4.7 V.
trouble
Action of
controller
Problem that
appears on • The snap shot data downloaded to a personal computer are not displayed normally.
machine
• The error codes of the VHMS system are not recorded in the failure history of the machine monitor.
Related • The 7-segment LED of the VHMS controller displays n3 o 31 (displays the code 2 characters by 2).
information • The blow-by pressure can be checked by downloading the data to a personal computer after per-

Sensor 5-V power sup-
1 If error code [DBB5KP] is displayed, perform troubleshooting for it first.
ply defective
P43 Voltage
Between (B) and (A) 4.5 – 5.5 V
2 sor defective
(Internal defect) Between (C) and (A) 0.3 – 0.7 V
The voltage of the pressure sensor is measured with the wiring harness
connected. Accordingly, if the voltage is abnormal, check the wiring har-
ness and controller for another cause of the trouble, and then judge.
Possible
causes and Blow-by pressure sen-
Referring to TESTING AND ADJUSTING, check the sensor for sticking oil,
standard value 3 sor defective (External
dust, water, etc. and clean it.
in normal state defect)
Referring to TESTING AND ADJUSTING, check the sensor for defective
4 sor defective (Installa-
installation and repair it.
tion defective)
Hot short circuit in wir- out troubleshooting.
5 ing harness (Contact
with 24-V circuit) Between wiring harness between VC2A (female)
Voltage Max. 1 V
(18) and P43 (female) (C) and grounding
VHMS controller out troubleshooting.
6
defective CV02A Voltage
Between (18) and (13) 0.3 – 0.7 V
30 PC2000-8
Circuit diagram related to blow-by pressure sensor
PC2000-8 31
Failure code [DHH2KA] Hydraulic oil filter Sensor Failure (or change of
User code Failure code Hydraulic oil filter Sensor Failure
Trouble
— DHH2KA (VHMS controller system)
Contents of • While engine was stopped, signal circuit of hydraulic oil filter clogging sensor was disconnected
trouble (disconnected with GND).
Action of
controller
Problem that
appears on • None in particular.
machine
information • VHMS controller 7-segment LED display: “n5” o “53” (codes are displayed by 2 digits)

Clogging of hydraulic
1 oil filter (when the sys- Check the hydraulic oil filter, and replace it if clogged.
tem is normal)
filter clogging switch
2 P04 (male) Hydraulic oil filter Resistance
tion or short circuit) Between (1) and (2)
standard value 3
tion or defective con- Wiring harness between CV02B (female) (1) –
in normal state tact in connector) Resistance Max. 1 z
P40 (female) (1)
V circuit) Between wiring harness CV02B (female) (1) –
Voltage Max. 1 V
Defective VHMS
5 Between CV02B Value in normal state Max. 1 V
controller
(female) (1) and chas-
sis ground Value when clogged 20 – 30 V
Circuit diagram related to hydraulic oil filter clogging sensor
32 PC2000-8
Failure code [DHPEKX] VR1/P1F Pump P. Sensor Abnormality 1

User code Failure code VR1/P1F Pump P. Sensor Abnormality
Trouble
E07 DHPEKX (Pump controller 1 system)
Contents of
trouble
Action of
• Restricts the pump control (PQ control) function.
controller
Problem that
• Pump (PQ control) cannot be controlled.
appears on
• Pump (CO control) cannot be controlled.
machine
Related • Input from the pump pressure sensor can be checked with monitoring function.
information (Code: 01124 P1F system pump pressure)

1
Defective pump pres- engine and carry out troubleshooting in each case.
sure sensor (Internal
2 P32 Voltage
disconnection or short
circuit) Between (3) and (1) Power supply 4.5 – 5.5 V
Between (2) and (1) Signal 0.5 – 4.5 V
Disconnection in wiring Wiring harness between CP01 (female) (9) – Resistance Max. 1 z
3
Resistance Max. 1 z
Possible tact in connector) P32 (female) (1)
causes and Wiring harness between CP01 (female) (22) –
P32 (female) (3)
GND circuit)
V circuit)
Voltage Max. 6 V
6
34 PC2000-8
Circuit diagram related to VR1/P1F pump pressure sensor
PC2000-8 35
Failure code [DHPFKX] VL1/P1R Pump P. Sensor Abnormality 1

User code Failure code VL1/P1R Pump P. Sensor Abnormality
Trouble
E07 DHPFKX (Pump controller 1 system)
Contents of
trouble
Action of
controller
Problem that
appears on
machine
information (Code: 01125 P1R system pump pressure)

1
2 P25 Voltage
3
Resistance Max. 1 z
P25 (female) (3)
GND circuit)
V circuit)
Voltage Max. 6 V
6
36 PC2000-8
Circuit diagram related to VL1/P1R pump pressure sensor
PC2000-8 37
Failure code [DHPGKX] VR2/P2F Pump P. Sensor Abnormality 1

User code Failure code VR2/P2F Pump P. Sensor Abnormality
Trouble
E07 DHPGKX (Pump controller 1 system)
Contents of
trouble
Action of
controller
Problem that
appears on
machine
information (Code: 01126 P2F system pump pressure)

1
2 P33 Voltage
3
Resistance Max. 1 z
P33 (female) (3)
GND circuit)
V circuit)
Voltage Max. 6 V
6
38 PC2000-8
Circuit diagram related to VR2/P2F pump pressure sensor
PC2000-8 39
Failure code [DHPHKX] VL2/P2R Pump P. Sensor Abnormality 1

User code Failure code VL2/P2R Pump P. Sensor Abnormality
Trouble
E07 DHPHKX (Pump controller 1 system)
Contents of
trouble
Action of
controller
Problem that
appears on
machine
information (Code: 01127 P2R system pump pressure)

1
2 P26 Voltage
3
Resistance Max. 1 z
P26 (female) (3)
GND circuit)
V circuit)
Voltage Max. 6 V
6
40 PC2000-8
Circuit diagram related to VL2/P2R pump pressure sensor
PC2000-8 41
Failure code [DHPSKX] Auto Grease Press Sensor Abnormality 1

User code Failure code Auto Grease Press Sensor Abnormality
Trouble
— DHPSKX (Pump controller 2 system)
Contents of
trouble
Action of
controller
Problem that
appears on • Caution for automatic lubrication cannot be judged.
machine
Related • Input from the automatic greasing pressure sensor can be checked with monitoring function.
information (Code: 13901 Automatic lubrication pressure sensor voltage)

Defective sensor
1 If failure code [dA25KP] is displayed, carry out troubleshooting for it first.
power supply system
Defective grease pump a Prepare with starting switch OFF, then turn starting switch ON and carry
discharge pressure out troubleshooting.
2 sensor (Internal dis- P48 (male) Voltage
connection or short cir- Between (B) and (A) Power supply 4.5 – 5.5 V
cuit) Between (C) and (A) Signal 0.5 – 4.5 V
harness (Disconnec- P48 (female) (C)
3
Resistance Max. 1 z
tact in connector) P48 (female) (A)
P48 (female) (B)
causes and
P48 (female) (A) and chassis ground
GND circuit)
P48 (female) (B) and chassis ground
P48 (female) (A) and chassis ground
V circuit)
Voltage Max. 6 V
P48 (female) (B) and chassis ground
Defective pump
6 CP04 Voltage
controller 2
Between (22) and (21) 4.5 – 5.5 V
Between (3) and (21) 0.5 – 4.5 V
42 PC2000-8
Circuit diagram related to auto grease pressure sensor
PC2000-8 43
Failure code [DHPTKX] Fan(RAD) Pump P. Sensor Open Circuit 1

User code Failure code Fan(RAD) Pump P. Sensor Open Circuit
Trouble
— DHPTKX (Pump controller 1 system)
Contents of
trouble
Action of
• Operates the system using the backup function
controller
Problem that
appears on • Data for the machine control cannot be acquired.
machine
Related • Input from the fan (radiator) pump pressure sensor can be checked with monitoring function.
information (Code: 01133 RAD fan pump pressure sensor voltage)

Defective 5 V sensor If failure code [dA25KP] is also indicated, carry out troubleshooting for it
1
Defective fan (radia- a Prepare with starting switch OFF, then carry out troubleshooting without
tor) pump pressure turning starting switch ON.
connection or short cir- Between (3) and (1) 4.5 – 5.5 V
cuit) Between (2) and (1) 0.5 – 4.5 V
3
Resistance Max. 1 z
P35 (female) (3)
GND circuit)
V circuit)
Voltage Max. 6 V
Defective pump If causes 1 – 5 are not detected, engine controller may be defective.
6
44 PC2000-8
Circuit diagram related to fan (radiator) pump pressure sensor
PC2000-8 45
Failure code [DHPUKX] Fan(O/C) Pump P. Sensor Open Circuit 1

User code Failure code Fan(O/C) Pump P. Sensor Open Circuit
Trouble
— DHPUKX (Pump controller 1 system)
Contents of
trouble
Action of
• Operates the system using the backup function
controller
Problem that
appears on • Data for the machine control cannot be acquired.
machine
Related • Input from the fan (oil cooler) pump pressure sensor can be checked with monitoring function.
information (Code: 01135 Oil cooler fan pump pressure sensor voltage)

1
Defective fan pump turning starting switch ON.
pressure sensor (Inter-
2 P35 (male) Voltage
short circuit) Between (3) and (1) 4.5 – 5.5 V
Between (2) and (1) 0.5 – 4.5 V
3
Resistance Max. 1 z
P34 (female) (3)
GND circuit)
V circuit)
Voltage Max. 6 V
Defective pump If causes 1 – 5 are not detected, engine controller may be defective.
6
46 PC2000-8
Circuit diagram related to fan (oil cooler) pump pressure sensor
PC2000-8 47
Failure code [DHS3KX] Arm Dig PPC Press Sensor Abnormality 1

User code Failure code Arm Dig PPC Press Sensor Abnormality
Trouble
— DHS3KX (Pump controller 2 system)
Contents of
trouble
Action of
controller
Problem that
appears on • Arm IN cannot be judged.
machine
Related • Input from arm IN PPC pressure sensor can be checked with monitoring function.
information (Code: 07201 Arm IN PPC pressure sensor voltage)

1
Defective arm IN PPC turning starting switch ON.
pressure sensor (Inter-
short circuit) Between (3) and (1) 4.5 – 5.5 V
Between (2) and (1) 0.5 – 4.5 V
Resistance Max. 1 z
3
Resistance Max. 1 z
P06 (female) (3)
causes and
GND circuit)
V circuit)
Voltage Max. 6 V
Defective pump
6 CP04 Voltage
controller 2
Between (22) and (21) 4.5 – 5.5 V
Between (8) and (21) 0.5 – 4.5 V
48 PC2000-8
Circuit diagram related to arm IN PPC pressure sensor
PC2000-8 49
Failure code [DHS4KX] Bucket Curl PPC Press Sensor Abnormality 1

User code Failure code Bucket Curl PPC Press Sensor Abnormality
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on • Bucket Curl cannot be judged.
machine
Related • Input from bucket Curl PPC pressure sensor can be checked with monitoring function.
information (Code: 07302 Bucket Curl PPC pressure sensor voltage)

1
Defective bucket Curl turning starting switch ON.
PPC pressure sensor
tion or short circuit) Between (3) and (1) 4.5 – 5.5 V
Between (2) and (1) 0.5 – 4.5 V
3
Resistance Max. 1 z
P03 (female) (3)
causes and
GND circuit)
V circuit)
Voltage Max. 6 V
Defective pump
6 CP04 Voltage
controller 2
Between (22) and (21) 4.5 – 5.5 V
Between (19) and (21) 0.5 – 4.5 V
50 PC2000-8
Circuit diagram related to bucket curl PPC pressure sensor
PC2000-8 51
Failure code [DHS8KX] Boom Raise PPC Press Sensor Abnormality 1

User code Failure code Boom Raise PPC Press Sensor Abnormality
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on • Boom Raise cannot be judged.
machine
Related • Input from boom Raise PPC pressure sensor can be checked with monitoring function.
information (Code: 07401 Boom Raise PPC pressure sensor voltage)

1
Defective boom Raise turning starting switch ON.
PPC pressure sensor
Between (2) and (1) 0.5 – 4.5 V
3
Resistance Max. 1 z
P01 (female) (3)
causes and
GND circuit)
V circuit)
Voltage Max. 6 V
Defective pump
6 CP04 Voltage
controller 2
Between (22) and (21) 4.5 – 5.5 V
Between (20) and (21) 0.5 – 4.5 V
52 PC2000-8
Circuit diagram related to boom RAISE PPC pressure senso0
PC2000-8 53
Failure code [DHS9KX] Boom Lower PPC Press Sensor Abnormality 1

User code Failure code Boom Lower PPC Press Sensor Abnormality
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on • Boom Lower cannot be judged.
machine
Related • Input from boom Lower PPC pressure sensor can be checked with monitoring function.
information (Code: 07501 Boom Lower PPC pressure sensor voltage)

1
Defective boom Lower turning starting switch ON.
PPC pressure sensor
Between (2) and (1) 0.5 – 4.5 V
3
Resistance Max. 1 z
P02 (female) (3)
causes and
GND circuit)
V circuit)
Voltage Max. 6 V
Defective pump
6 CP04 Voltage
controller 2
Between (22) and (21) 4.5 – 5.5 V
Between (14) and (21) 0.5 – 4.5 V
54 PC2000-8
Circuit diagram related to boom LOWER PPC pressure sensor
PC2000-8 55
Failure code [DHSAKX] Swing Right PPC Press Sensor Abnormality 1

User code Failure code Swing Right PPC Press Sensor Abnormality
Trouble
— DHSAKX (Pump controller 2 system)
Contents of
• Signal voltage from the swing right PPC pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of
controller
Problem that
appears on • Swing right cannot be judged.
machine
Related • Input from the swing right PPC pressure sensor can be checked with monitoring function.
information (Code: 09004 Swing right PPC pressure sensor voltage)

Defective sensor If failure code [dA25KP] is also indicated, carry out troubleshooting for it
1
Defective swing right bleshooting.
2 PPC pressure sensor P08 Voltage
(Internal defect) Between (3) and (1) 4.5 – 5.5 V
Between (2) and (1) 0.5 – 4.5 V
harness (Disconnec- A02 – P08 (female) (3)
3
Resistance Max. 1 z
tact in connector) A02 – P08 (female) (1)
Possible
A02 – P07 (female) (2)
standard value
GND circuit) Between wiring harness CP04 (female) (1) – A02
5 ness (Contact with 24 Voltage 4.5 – 5.5 V
A02 – P08 (female) (3) and chassis ground
V circuit)
Between wiring harness CP04 (female) (1) – A02
Voltage 0.5 – 4.5 V
bleshooting.
Defective pump
6 CP04 Voltage
controller 2
Between (22) and (21) 4.5 – 5.5 V
Between (1) and (21) 0.5 – 4.5 V
56 PC2000-8
Circuit diagram related to swing RIGHT PPC pressure sensor
PC2000-8 57
Failure code [DHSBKX] Swing Left PPC Press Sensor Abnormality 1

User code Failure code Swing Left PPC Press Sensor Abnormality
Trouble
— DHSBKX (Pump controller 2 system)
Contents of
• Signal voltage from the swing left PPC pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of
controller
Problem that
appears on • Swing left cannot be judged.
machine
Related • Input from the swing left PPC pressure sensor can be checked with monitoring function.
information (Code: 09003 Swing left PPC pressure sensor voltage)

Defective sensor If failure code [dA25KP] is also indicated, carry out troubleshooting for it
1
Defective swing left bleshooting.
2 PPC pressure sensor P07 Voltage
(Internal defect) Between (3) and (1) 4.5 – 5.5 V
Between (2) and (1) 0.5 – 4.5 V
harness (Disconnec- A02 – P07 (female) (3)
3
Resistance Max. 1 z
tact in connector) A02 – P07 (female) (1)
Possible
A02 – P07 (female) (2)
standard value
GND circuit) Between wiring harness CP04 (female) (7) – A02
5 ness (Contact with 24 Voltage 4.5 – 5.5 V
A02 – P03 (female) (3) and chassis ground
V circuit)
Between wiring harness CP04 (female) (7) – A02
bleshooting.
Defective pump
6 CP04 Voltage
controller 2
Between (22) and (21) 4.5 – 5.5 V
Between (7) and (21) 0.5 – 4.5 V
58 PC2000-8
Circuit diagram related to swing LEFT PPC pressure sensor
PC2000-8 59
Failure code [DHSCKX] Arm Dump PPC Press Sensor Abnormality 1

User code Failure code Arm Dump PPC Press Sensor Abnormality
Trouble
— DHSCKX (Pump controller 2 system)
Contents of
trouble
Action of
controller
Problem that
appears on • Arm dump cannot be judged.
machine
Related • Input from the arm dump PPC pressure sensor can be checked with monitoring function.
information (Code: 07601 Arm dump PPC pressure sensor voltage)

1
Defective arm dump turning starting switch ON.
PPC pressure sensor
Between (2) and (1) 0.5 – 4.5 V
3
Resistance Max. 1 z
P05 (female) (3)
causes and
GND circuit)
V circuit)
Voltage Max. 6 V
Defective pump
6 CP04 Voltage
controller 2
Between (22) and (21) 4.5 – 5.5 V
Between (2) and (21) 0.5 – 4.5 V
60 PC2000-8
Circuit diagram related to arm OUT PPC pressure sensor
PC2000-8 61
Failure code [DHSDKX] Bucket Dump PPC Press Sensor Abnormality 1

User code Failure code Bucket Dump PPC Press Sensor Abnormality
Trouble
— DHSDKX (Pump controller 2 system)
Contents of
trouble
Action of
controller
Problem that
appears on • Bucket dump cannot be judged.
machine
Related • Input from bucket dump PPC pressure sensor can be checked with monitoring function.
information (Code: 07303 Bucket DUMP PPC pressure sensor voltage)

1
Defective bucket a Prepare with starting switch OFF, then carry out troubleshooting without
DUMP PPC pressure turning starting switch ON.
connection or short cir- Between (3) and (1) 4.5 – 5.5 V
cuit) Between (2) and (1) 0.5 – 4.5 V
3
Resistance Max. 1 z
P04 (female) (3)
causes and
GND circuit)
V circuit)
Voltage Max. 6 V
Defective pump
6 CP04 Voltage
controller 2
Between (22) and (21) 4.5 – 5.5 V
Between (13) and (21) 0.5 – 4.5 V
62 PC2000-8
Circuit diagram related to bucket DUMP PPC pressure sensor
PC2000-8 63
SEN02100-00

© 2006 KOMATSU
All Rights Reserved
64
SEN02101-00
PC2000-8

PC2000-8 20001 and up
Failure code [DUM3KB] Auto Grease Caution LED Short Circuit ........................................................ 3
Failure code [DUM4KB] FAN Reverse LED Short Circuit .................................................................... 4
Failure code [DV20KB] Travel Alarm S/C ............................................................................................ 5
Failure code [DW41KA] Swing Priority Sol Open Circuit ..................................................................... 7
Failure code [DW41KB] Swing Priority Sol Short Circuit...................................................................... 9
Failure code [DW45KA] Swing Brake Sol. Disc. .................................................................................11
Failure code [DW45KB] Swing Brake Sol. S/C .................................................................................. 14
Failure code [DW91KA] Straight-Travel Sol. Disc. ............................................................................. 16
Failure code [DW91KB] Straight-Travel Sol. S/C ............................................................................... 18
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc.................................................................. 20
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C................................................................... 21
Failure code [DW7BKA] Fan Motor (RAD) Reverse Sol Open Circuit ............................................... 22
Failure code [DW7BKB] Fan Reverse Sol. S/C ................................................................................. 24
Failure code [DW7HKA] Fan Motor(O/C) Reverse Sol Open Circuit ................................................. 26
Failure code [DW7HKB] Fan Motor(O/C) Reverse Sol Short Circuit ................................................. 28
PC2000-8 1
Failure code [DWA3KA] Arm throttle Valve/L Sol Open Circuit .......................................................... 30
Failure code [DWA3KB] Arm throttle Valve/L Sol Short Circuit .......................................................... 32
Failure code [DWA4KA] Arm throttle Valve/R Sol Open Circuit ......................................................... 34
Failure code [DWA4KB] Arm throttle Valve/R Sol Short Circuit.......................................................... 36
Failure code [DWA5KA] Auto Grease Sol Open Circuit ..................................................................... 38
Failure code [DWA5KB] Auto Grease Sol Short Circuit ..................................................................... 40
Failure code [DWA6KA] Boom throttle Valve Sol Open Circuit .......................................................... 41
Failure code [DWA6KB] Boom throttle Valve Sol Short Circuit .......................................................... 43
Failure code [DWK0KA] 2-stage Relief Sol. Disc. .............................................................................. 45
Failure code [DWK0KB] 2-stage Relief Sol. S/C ................................................................................ 47
Failure code [DWK2KA] Back Press Comp Valve Sol Open Circuit................................................... 48
Failure code [DWK2KB] Back Press Comp Valve Sol Short Circuit ................................................... 49
2 PC2000-8

Failure code [DUM3KB] Auto Grease Caution LED Short Circuit 1
User code Failure code Auto Grease Caution LED Short Circuit
Trouble
— DUM3KB (Pump controller 1 system)
Contents of
• Short circuit was detected in the automatic lubrication abnormal LED circuit
trouble
Action of
• Stops output to the circuit.
controller
Problem that
appears on • LED is not lit up
machine
• The input status (ON or OFF) from the automatic lubrication abnormality LED can be checked with
Related
the monitoring function.
information
Monitoring code: 03702 Controller output 3

Possible Ground fault in wiring
causes and 1 harness (Short circuit
Wiring harness between CP03 (female) (8) – L22
standard value with GND circuit) Resistance Min. 1 Mz
in normal state (female) (1) and chassis ground
Defective pump con- If cause 1 is not found, the pump controller may be defected. (Trouble-
2
troller 1 shooting cannot be carried out since the trouble is in the system.)
Circuit diagram related to auto greasing caution LED output
PC2000-8 3
Failure code [DUM4KB] FAN Reverse LED Short Circuit 1

User code Failure code FAN Reverse LED Short Circuit
Trouble
— DUM4KB (Pump controller 1 system)
Contents of
• Short circuit was detected in the fan reverse rotation abnormality LED circuit
trouble
Action of
• Stops output to the circuit.
controller
Problem that
appears on • LED is not lit up
machine
• The input status (ON or OFF) from the fan reverse rotation abnormality LED can be checked with
Related
information
(Monitoring code: 03702 Controller output 3)

standard value GND circuit) Resistance Min. 1 Mz
in normal state L22 (female) (1) and chassis ground
Defective pump con- If cause 1 is not found, the pump controller may be defected. (Trouble-
2
troller 1 shooting cannot be carried out since the trouble is in the system.)
Circuit diagram related to fan reverse warning LED output
4 PC2000-8
Failure code [DV20KB] Travel Alarm S/C 1

User code Failure code Travel Alarm S/C
Trouble
— DV20KB (Pump controller 2 system)
Contents of
• Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit.
trouble
Action of • Power to the travel alarm circuit is switched OFF.
machine moni- • Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
tor unless the engine starting switch is once turned OFF.
Problem that
appears on • The travel alarm does not sound.
machine
Related • Operation of the travel alarm (ON or OFF) can be checked in the monitoring function.
information (Code No. 03701: Controller output 2)

M14 (female) Travel lever Voltage
Travel alarm defective
1 Neutral Max. 1 V
(Internal defect) Between (1) – (2)
Operated 20 – 30 V
If the above voltage is normal but the travel alarm does not operate, the
Possible travel alarm is defective.
causes and
standard value Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without
in normal state ing harness turning starting switch ON.
2
(Contact with ground- Between wiring harness between CP06 (female)
(18) – M14 (female) (1) and grounding
Pump controller 2 CP06 Travel lever Voltage
3
defective
Between (18) – chassis Neutral Max. 1 V
ground Operated 20 – 30 V
PC2000-8 5
Circuit diagram related to travel alarm
6 PC2000-8
Failure code [DW41KA] Swing Priority Sol Open Circuit 1

User code Failure code Swing Priority Sol Open Circuit
Trouble
— DW41KA (Pump controller 2 system)
Contents of
• No current flows to the swing priority solenoid circuit, when power is supplied to the circuit.
trouble
Action of
• None in particular (The solenoid does not function as there is no current flowing to it)
machine moni-
• When the failure cause disappears of itself, the machine operation returns to normalcy.
tor
Problem that
• When the boom is raised and the machine is swung simultaneously in the swing priority mode, the
appears on
swing speed is low (the oil flow in the swing circuit is kept low).
machine
• Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 02301: Solenoid 2)
Related
• Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
information
solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON
or OFF, refer to the troubleshooting under failure code [DW41KB].)

Swing priority solenoid a Prepare with starting switch OFF, then carry out troubleshooting without
defective turning starting switch ON.
1
(Internal disconnec- V02 (male) Resistance
tion) Between (2) – (1) 20 – 60 z
harness
Wiring harness from CP06 (female) (38) – V02
Possible 2 (Disconnection or Resistance Max. 1 z
(female) (1)
causes and defective contact with
standard value connector) Wiring harness between V02 (female) (2) –
Resistance Max. 1 z
in normal state CP06 (female) (3), (23)
Short-circuiting of wir- a Prepare with starting switch OFF, then turn starting switch ON and carry
ing harness out troubleshooting.
3
(Contact with 24 V cir- Between wiring harness between CP06 (female)
cuit) Voltage Max. 1 V
(38) – V02 (female) (1) and grounding
Pump controller 2 turning starting switch ON.
4
defective CP06 (female) Resistance
Between (38) – chassis ground 20 – 60 z
PC2000-8 7
Electric circuit diagram related to swing priority solenoid
8 PC2000-8
Failure code [DW41KB] Swing Priority Sol Short Circuit 1

User code Failure code Swing Priority Sol Short Circuit
Trouble
— DW41KB (Pump controller 2 system)
Contents of
• Abnormal current flew to the swing priority solenoid, when power was supplied to the circuit.
trouble
Action of • Power supply to the swing priority solenoid circuit is switched OFF.
machine moni- • Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
tor unless the engine starting switch is once turned OFF.
Problem that
• When the boom is raised and the machine is swung simultaneously in the swing priority mode, the
appears on
swing speed is low (the oil flow in the swing circuit is kept low).
machine
Related • Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02301: Solenoid 2)

Swing priority solenoid turning starting switch ON.
defective V02 (male) Resistance
1
ing or grounding fault) Between (1) – (2) 20 – 60 z
Between (1) and grounding Min. 1 Mz
Possible 2
causes and ing circuit) Resistance Min. 1 Mz
standard value
in normal state
Swing priority switch
CP06 Left work equipment Voltage
Pump controller 2 control lever
3
defective OFF + NEUTRAL Max. 1 V
Between (38) – chassis Swing priority mode +

ground Swing operation +
20 – 30 V
(When boom or bucket
is operated)
PC2000-8 9
Electric circuit diagram related to swing priority solenoid
10 PC2000-8
Failure code [DW45KA] Swing Brake Sol. Disc. 1

User code Failure code Swing Brake Sol. Disc.
Trouble
E03 DW45KA (Pump controller 2 system)
Contents of
• No current flows at output to swing brake solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
Problem that
appears on • Machine cannot swing (The swing holding brake cannot be released).
machine
• Operating condition of swing brake solenoid (ON/OFF) can be checked with monitoring function.
(Code 02300: Solenoid 1)
• If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing
brake release switch in release position (Swing holding brake does not work, however, when
Related machine stops).
information • Keep the swing lock switch in the OFF position and the swing holding brake release switch in the
RELEASE position during troubleshooting.
• Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON
or OFF, refer to the troubleshooting under failure code [DW45KB].)

Defective swing hold- a Prepare with starting switch OFF, then carry out troubleshooting without
ing brake solenoid turning starting switch ON.
1
tion) Between (1) – (2) 20 – 60 z
Defective assembled- a Prepare with starting switch OFF, then carry out troubleshooting without
type diode D01 turning starting switch ON.
2
(Internal disconnec- D01 (male) Digital circuit tester Continuity
tion) Between (7) – (3) Diode mode There is continuity
Possible Defective swing lock turning starting switch ON.
causes and switch S04 (female) Switch Resistance
3
standard value (Internal disconnec-
tion) OFF Max. 1 z
in normal state Between (3) – (4)
LOCK (ON) Min. 1 Mz
Disconnection in wiring Resistance Max. 1 z
R12 (female) (2), (1)
harness
Wiring harness between CP06 (female) (7) – A03
– A01 – A04 – D01 (female) (7)
connector) Wiring harness between D01 (female) (3) – JB2 –
Resistance Max. 1 z
R12 (female) (3)
Wiring harness between R12 (female) (5) – JB72
Resistance Max. 1 z
– A05 – A09 – V20 (female) (1)
PC2000-8 11

Voltage Max. 1 V
D01 (female) (7)
Hot short (Short circuit
Wiring harness between CP06 (female) (7) – A03
5 with 24V circuit) in wir- Resistance Max. 1 z
Possible – A01 – A04 – D01 (female) (7)
ing harness
causes and Wiring harness between D01 (female) (3) – JB2 –
Resistance Max. 1 z
standard value R12 (female) (3)
in normal state Wiring harness between R12 (female) (5) – JB72
Resistance Max. 1 z
– A05 – A09 – V20 (female) (1)
Defective pump con-
6 CP06 (female) Disconnect D01 and Resistance
troller 2
Between (7) – connect pins (3) and (7)
on female side directly. 20 – 60 z
chassis ground
12 PC2000-8
Circuit diagram related to swing holding brake solenoid of pump controller
PC2000-8 13
Failure code [DW45KB] Swing Brake Sol. S/C 1

User code Failure code Swing Brake Sol. S/C
Trouble
E03 DW45KB (Pump controller 2 system)
Contents of
• Abnormal current flowed at output to swing brake solenoid circuit.
trouble
Action of • Turns output to swing brake solenoid circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Machine cannot swing. (The swing holding brake cannot be released).
machine
• Operating condition of swing brake solenoid (ON/OFF) can be checked with monitoring function.
Related
• If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing
information
brake release switch to release position (Swing holding brake does not work, however, when machine
stops).

Defective swing hold- turning starting switch ON.
ing brake solenoid V05A, V05B (male) Resistance
1
(Internal short circuit or
ground fault) Between (2) – (1) 20 – 60 z
Between (2) – chassis ground Min. 1 Mz
Possible harness
2
causes and (Short circuit with GND Wiring harness between CP06 (female) (7) –
standard value circuit) D01 (7), (3) – R12 (female) (3), (5) – V20 Resistance Min. 1 Mz
in normal state (female) (1) and chassis ground
bleshooting.
CP06 Swing lever Voltage
Defective pump con- Max. 1 V
3
troller 2 All levers in neutral (12 sec. after setting in
Between (7) – neutral)
chassis ground
Work equipment or
20 – 30 V
swing operated
14 PC2000-8
Circuit diagram related to swing holding brake solenoid of pump controller
PC2000-8 15
Failure code [DW91KA] Straight-Travel Sol. Disc. 1

User code Failure code Straight-Travel Sol. Disc.
Trouble
— DW91KA (Pump controller 2 system)
Contents of
• No current flows to the straight travel solenoid circuit, when power is supplied to the circuit.
trouble
Action of • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Problem that
appears on • When both tracks and work equipment are operated simultaneously, the machine deviates.
machine
• Operation of the straight travel solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 02300: Solenoid 1)
Related
• Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn
information
the solenoid output ON when checking the solenoid again after repairing it. (For how to turn power
ON or OFF, refer to the troubleshooting under failure code [DW91KB].)
Straight travel a Prepare with starting switch OFF, then carry out troubleshooting without
solenoid defective turning starting switch ON.
1
(Internal disconnec- V07 (male) Resistance value
tion) Between (1) and (2) 20 – 60 z
harness
Wiring harness from CP06 (female) (5) to V07 Resistance
Possible 2 (Disconnection or Max. 1 z
(female) (1) value
causes and defective contact with
standard value connector) Wiring harness between V03 (female) (1) and Resistance
Max. 1 z
in normal state grounding value
Hot short circuit in wir- a Prepare with starting switch OFF, then turn starting switch ON and carry
ing harness out troubleshooting.
3
(Contact with 24 V cir- Between wiring harness between CP06 (female)
cuit) Voltage Max. 1 V
4
defective CP06 (female) Resistance value
Between (5) – (13) 20 – 60 z
16 PC2000-8
Electrical diagram related to straight travel solenoid
PC2000-8 17
Failure code [DW91KB] Straight-Travel Sol. S/C 1

User code Failure code Straight-Travel Sol. S/C
Trouble
— DW91KB (Pump controller 2 system)
Contents of
• Abnormal current flew to the straight travel circuit, when power was supplied to the circuit.
trouble
• Power supply to the straight travel circuit is switched OFF.
Action of
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Problem that
appears on • When both tracks and work equipment are operated simultaneously, the machine deviates.
machine
Related • Operation of the straight travel solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02300: Solenoid 1)

Straight travel sole- turning starting switch ON.
noid defective V07 (male) Resistance value
1
ing or grounding fault) Between (1) and (2) 20 – 60 z
Possible Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without
causes and 2
standard value (Contact with ground- Between wiring harness between CP06 (female) Resistance
ing circuit) Min. 1 Mz
in normal state (5) – V07 (female) (1) and grounding value
bleshooting.
CP06 Control lever Voltage
Pump controller 2
3 NEUTRAL Max. 1 V
defective
Between (5) and Both tracks operation +
grounding Work equipment opera- 20 – 30 V
tion
18 PC2000-8
Electrical diagram related to travel junction solenoid
PC2000-8 19
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc. 1

User code Failure code Bucket Curl Hi Cancel Sol. Disc.
Trouble
— DW4XKA (Pump controller 2 system)
Contents of
• Open error was detected in the bucket digging Hi cancel solenoid circuit.
trouble
Action of
controller
Problem that
appears on • The bucket Hi cancel valve cannot work.
machine
• The input status (ON or OFF) from the bucket digging Hi cancel circuit can be checked with the
Related
monitoring function.
information
(Code: 02301 Solenoid 2 bucket Hi cancel)

Defective bucket dig- a Prepare with starting switch OFF, then carry out troubleshooting without
ging Hi cancel solenoid turning starting switch ON.
1
valve (Internal discon- V19 (male) Resistance
nection) Between (1) and (2) 20 – 60 z
harness (Disconnec- Wiring harness between CP06 (female) (13) –
Possible 2 Resistance Max. 1 z
tion or defective con- V19 (female) (2)
causes and tact in connector)
Resistance Max. 1 z
in normal state V19 (female) (1)
out troubleshooting
V circuit) Wiring harness between CP06 (female) (25) –
Voltage Max. 1 V
V19 (female) (1) and chassis ground
Defective pump con- turning starting switch ON.
4
troller 2 CP06 Resistance
Between (25) and chassis ground 20 – 60 z
Circuit diagram related to bucket CURL high cancel solenoid
20 PC2000-8
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C 1

User code Failure code Bucket Curl Hi Cancel Sol. S/C
Trouble
— DW4XKB (Pump controller 2 system)
Contents of
• Short circuit was detected in the bucket digging Hi cancel solenoid circuit.
trouble
Action of • Stops output to the circuit.
Problem that
appears on • The bucket Hi cancel valve cannot work.
machine
• The input status (ON or OFF) from the bucket digging Hi cancel solenoid valve can be checked with
Related
information
(Code: 02301 Solenoid 2 bucket Hi cancel)

Defective bucket dig- turning starting switch ON.
ging Hi cancel solenoid V19 (male) Resistance
1
valve (Internal discon-
Between (1) and chassis ground Min. 1 Mz
causes and 2 harness (Contact with Resistance Min. 1 Mz
standard value V19 (female) (2) and chassis ground
GND circuit)
in normal state Wiring harness between CP06 (female) (25) –
bleshooting.
Work equipment control
3 lever
troller 2
At neutral Max. 1 V
Between (25) and
chassis ground When boom raise +
20 – 30 V
Bucket curl
Circuit diagram related to bucket CURL high cancel solenoid
PC2000-8 21
Failure code [DW7BKA] Fan Motor (RAD) Reverse Sol Open Circuit 1
User code Failure code Fan Motor (RAD) Reverse Sol Open Circuit
Trouble
— DW7BKA (Pump controller 1 system)
Contents of
• When signal is output to RAD fan reverse solenoid circuit, no current flows.
trouble
Action of • None in particular (The solenoid does not function as there is no current flowing to it)
Problem that
appears on • Fan does not rotate in reverse.
machine
• Operating condition (ON/OFF) of RAD fan reverse solenoid can be checked with monitoring func-
Related tion. (Code 02303: Solenoid 4) (fan (RAD) reverse solenoid)
information • Since disconnection of solenoid is detected while output is turned ON, be sure to turn output ON
(rotate fan in reverse) when checking reproduction of failure after repair.

Defective RAD fan turning starting switch ON.
1 reverse solenoid (Inter-
V18 (female) Resistance
nal disconnection)
Between (1) – (2) 20 – 60 z
tion of defective con- V18 (female) (1)
causes and tact with connector)
standard value Wiring harness between V18 (female) (2) –
Resistance Max. 1 z
in normal state CP03 (female) (13)
Short-circuiting of wir- out troubleshooting.
with 24 V circuit) Between wiring harness between CP03 (female)
Voltage Max. 1 V
4
Between (25) and grounding 20 – 60 z
22 PC2000-8
Circuit diagram related to RAD fan
PC2000-8 23
Failure code [DW7BKB] Fan Reverse Sol. S/C 1

User code Failure code Fan Reverse Sol. S/C
Trouble
— DW7BKB (Pump controller 1 system)
Contents of
• When signal was output to RAD fan reverse solenoid circuit, abnormal current flowed.
trouble
Action of • Turns signal to RAD fan reverse solenoid circuit OFF.
Problem that
machine
• Operating condition (ON/OFF) of RAD fan reverse solenoid can be checked with monitoring func-
Related
tion.
information
(Code 02303: Solenoid 4) (fan (RAD) reverse solenoid)

Defective RAD fan
1 reverse solenoid (Inter- V18 (male) Resistance
nal disconnection) Between (1) – (2) 20 – 60 z
causes and 2
(25), – V18 (female) (1) and grounding
in normal state
carry out troubleshooting.
Fan reverse rotation
CP03 Voltage
Pump controller 1 mode
3
defective When reverse rotation
Max. 1 V
Between (25) and is turned OFF
grounding When reverse rotation
20 – 30 V
is turned ON
24 PC2000-8
Circuit diagram related to RAD fan
PC2000-8 25
Failure code [DW7HKA] Fan Motor(O/C) Reverse Sol Open Circuit 1

User code Failure code Fan Motor(O/C) Reverse Sol Open Circuit
Trouble
— DW7HKA (Pump controller 1 system)
Contents of
• When signal is output to O/C fan reverse solenoid circuit, no current flows.
trouble
Action of • None in particular (The solenoid does not function as there is no current flowing to it)
Problem that
machine
• Operating condition (ON/OFF) of O/C fan reverse solenoid can be checked with monitoring function.
Related (Code 02303: Solenoid 4)
information • Since disconnection of solenoid is detected while output is turned ON, be sure to turn output ON
(rotate fan in reverse) when checking reproduction of failure after repair.

Defective O/C fan turning starting switch ON.
1 reverse solenoid (Inter-
V17 (male) Resistance
nal disconnection)
Between (1) – (2) 20 – 60 z
tion of defective con- V17 (female) (1)
causes and tact with connector)
standard value Wiring harness between V17 (female) (2) – JB55
Resistance Max. 1 z
in normal state – JC14 – CP03 (female) (13)
Short-circuiting of wir- out troubleshooting.
with 24 V circuit) Between wiring harness between CP03 (female)
Voltage Max. 1 V
4
Between (35) and grounding 20 – 60 z
26 PC2000-8
Circuit diagram related to O/C fan
PC2000-8 27
Failure code [DW7HKB] Fan Motor(O/C) Reverse Sol Short Circuit 1

User code Failure code Fan Motor(O/C) Reverse Sol Short Circuit
Trouble
— DW7HKB (Pump controller 1 system)
Contents of
• When signal was output to O/C fan reverse solenoid circuit, abnormal current flowed.
trouble
Action of • Turns signal to O/C fan reverse solenoid circuit OFF.
Problem that
machine
Related • Operating condition (ON/OFF) of O/C fan reverse solenoid can be checked with monitoring function.
information (Code 02303: Solenoid 4)

1 reverse solenoid (Inter- V17 (male) Resistance
nal disconnection) Between (1) – (2) 20 – 60 z
causes and 2
(35), – V17 (female) (1) and grounding
in normal state
Fan reverse rotation
CP03 Voltage
Pump controller 1 mode
3
defective When reverse rotation
Max. 1 V
Between (35) and is turned OFF
grounding When reverse rotation
20 – 30 V
is turned ON
28 PC2000-8
Circuit diagram related to O/C fan
PC2000-8 29
Failure code [DWA3KA] Arm throttle Valve/L Sol Open Circuit 1

User code Failure code Arm throttle Valve/L Sol Open Circuit
Trouble
— DWA3KA (Pump controller 2 system)
Contents of
• Any current does not flow in the arm throttle valve (L) solenoid circuit.
trouble
Action of • None in particular. (Since any current does not flow, the solenoid does not operate.)
controller • If the cause of the failure disappears, the system resets itself.
Problem that
appears on • The arm throttle valve (L) does not work.
machine
Related • The output to the arm throttle valve (L) solenoid (current) can be checked in the monitoring function.
information (Code: 02302 Solenoid 3)

Defective arm throttle a Prepare with starting switch OFF, then carry out troubleshooting without
valve (L) solenoid turning starting switch ON.
1
(Internal short circuit or V04 (male) Resistance value
grounding fault) Between (1) and (2) 20 – 60 z
Wiring harness between LP06 (female) (3), (23) Resistance
2 nection in wiring or Max. 1 z
and V04 (female) (2) value
connector) Wiring harness between CP06 (female) (27) and Resistance
causes and Max. 1 z
V04 (female) (1) value
standard value
Short circuit with power out troubleshooting.
source in wiring har- Between wiring harness between CP06 (female)
3 Voltage Max. 1 V
ness (Contact with 24- (27) to V04 (female) (1) and grounding
V circuit) Between wiring harness between CP06 (female)
Voltage Max. 1 V
(27) to V04 (female) (1) and grounding
4
Between (27) and (3) (23) 20 – 60 z
30 PC2000-8
Circuit diagram related to arm throttle valve (L) solenoid
PC2000-8 31
Failure code [DWA3KB] Arm throttle Valve/L Sol Short Circuit 1

User code Failure code Arm throttle Valve/L Sol Short Circuit
Trouble
— DWA3KB (Pump controller 2 system)
Contents of
• An abnormal current flowed in the arm throttle valve (L) solenoid circuit.
trouble
• Turns off the output to the arm throttle valve (L) solenoid circuit.
Action of
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
controller
turned OFF.
Problem that
appears on • The arm throttle valve (L) does not work.
machine
Related • The output to the arm throttle valve (L) solenoid (current) can be checked in the monitoring function.

Defective arm throttle turning starting switch ON.
valve (L) solenoid V09 (male) Resistance value
1
Between (1) and ground Min. 1 Mz
Possible Short circuit with chas-
causes and Short circuit of wiring harness between CP06
sis ground in wiring Resistance
standard value 2 (female) (3), (23) and V04 (female) (2) with Min. 1 Mz
harness (Contact with value
in normal state ground
ground circuit)
Short circuit of wiring harness between CP06 Resistance
Min. 1 Mz
(female) (27) and V04 (female) (1) with ground value
bleshooting.
Pump controller 2 CP06 (female) Control lever Voltage
3
defective At neutral Max. 1 V
Between (27) and
(3) (23) When Boom raise +
20 – 30 V
Arm dump
32 PC2000-8
Circuit diagram related to arm throttle valve (L) solenoid
PC2000-8 33
Failure code [DWA4KA] Arm throttle Valve/R Sol Open Circuit 1

User code Failure code Arm throttle Valve/R Sol Open Circuit
Trouble
Contents of
• Any current does not flow in the arm throttle valve (R) solenoid circuit.
trouble
Problem that
appears on • The arm throttle valve (R) does not work.
machine
Related • The output to the arm throttle valve (R) solenoid (current) can be checked in the monitoring function.

Defective arm throttle a Prepare with starting switch OFF, then carry out troubleshooting without
valve (R) solenoid turning starting switch ON.
1
Wiring harness between CP06 (female) (3) and Resistance
causes and Max. 1 z
standard value
3 Voltage Max. 1 V
Voltage Max. 1 V
4
Between (37) and (13) 20 – 60 z
34 PC2000-8
Circuit diagram related to arm throttle valve (R) solenoid
PC2000-8 35
Failure code [DWA4KB] Arm throttle Valve/R Sol Short Circuit 1

User code Failure code Arm throttle Valve/R Sol Short Circuit
Trouble
Contents of
• An abnormal current flowed in the arm throttle valve (R) solenoid circuit.
trouble
• Turns off the output to the arm throttle valve (R) solenoid circuit.
Action of
controller
turned OFF.
Problem that
appears on • The arm throttle valve (R) does not work.
machine
Related • The output to the arm throttle valve (R) solenoid (current) can be checked in the monitoring function.

Defective arm throttle turning starting switch ON.
valve (L) solenoid V05 (male) Resistance value
1
Possible Short circuit with chas- turning starting switch ON.
causes and sis ground in wiring Short circuit of wiring harness between CP06 Resistance
standard value 2 Min. 1 Mz
harness (Contact with (female) (13) and V05 (female) (1) with ground value
in normal state ground circuit) Short circuit of wiring harness between CP06 Resistance
Min. 1 Mz
bleshooting.
Pump controller 2 CP06 Control lever Voltage
3
Between (37) and (13) When Arm dump +
20 – 30 V
Boom raise + Swing
36 PC2000-8
Circuit diagram related to arm throttle valve (R) solenoid
PC2000-8 37
Failure code [DWA5KA] Auto Grease Sol Open Circuit 1

User code Failure code Auto Grease Sol Open Circuit
Trouble
Contents of
• Open error was detected in the automatic greasing solenoid valve circuit
trouble
controller • If cause of failure disappears, the system resets itself.
Problem that
appears on • The automatic greasing cannot work.
machine
• The input status (ON or OFF) from the automatic greasing solenoid valve can be checked with the
Related
information
(code: 02303 Solenoid 4)

Defective automatic a Prepare with starting switch OFF, then carry out troubleshooting without
greasing solenoid turning starting switch ON.
1
tion or defective con- V25 (female) (1)
tact in connector) Wiring harness between CP03 (female) (13) –
V25 (female) (2)
causes and
standard value a Prepare with starting switch OFF, then turn starting switch ON and carry
in normal state out troubleshooting
Voltage Max. 1 V
Automatic greasing
CP03 Voltage
Defective pump con- operation
4
troller 1 When automatic greas-
Max. 1 V
Between (7) and ing is turned OFF
chassis ground When automatic greas-
20 – 30 V
ing is turned ON
38 PC2000-8
Circuit diagram related to auto grease solenoid
PC2000-8 39
Failure code [DWA5KB] Auto Grease Sol Short Circuit 1

User code Failure code Auto Grease Sol Short Circuit
Trouble
Contents of
• Short circuit was detected in the automatic greasing solenoid valve circuit.
trouble
Action of • Stops output to the automatic greasing solenoid circuit.
Problem that
appears on • The automatic greasing cannot work.
machine
• The input status (ON or OFF) from the automatic greasing solenoid valve can be checked with the
Related
information
(Monitoring code: 02303 Automatic greasing solenoid valve)

Internal failure of the turning starting switch ON.
automatic greasing V25 (male) Resistance
1
solenoid valve (Internal
disconnection) Between (1) and (2) 20 – 60 z
Possible Wiring harness between CP03 (female) (7) –
causes and V25 (female) (1) and ground chassis
standard value GND circuit)
V25 (female) (2) and ground chassis
Automatic greasing
CP03 Voltage
Defective pump con- operation
3
troller 1 When automatic greas-
Max. 1 V
Between (7) and chas- ing is turned OFF
sis ground When automatic greas-
20 – 30 V
ing is turned ON
Circuit diagram related to auto grease solenoid
40 PC2000-8
Failure code [DWA6KA] Boom throttle Valve Sol Open Circuit 1

User code Failure code Boom throttle Valve Sol Open Circuit
Trouble
Contents of
• Any current does not flow in the boom throttle valve solenoid circuit.
trouble
Problem that
appears on • The boom throttle valve does not work.
machine
Related • The output to the boom throttle valve solenoid (current) can be checked in the monitoring function.

Defective boom throt- a Prepare with starting switch OFF, then carry out troubleshooting without
tle valve solenoid turning starting switch ON.
1
Wiring harness between CP06 (female) (13) and Resistance
causes and Max. 1 z
standard value
3 Voltage Max. 1 V
Voltage Max. 1 V
4
Between (35) and ground 20 – 60 z
PC2000-8 41
Circuit diagram related to boom throttle valve solenoid
42 PC2000-8
Failure code [DWA6KB] Boom throttle Valve Sol Short Circuit 1

User code Failure code Boom throttle Valve Sol Short Circuit
Trouble
E06 DWA6KB (Pump controller 2 system)
Contents of
• An abnormal current flowed in the boom throttle valve solenoid circuit.
trouble
• Turns off the output to the boom throttle valve solenoid circuit.
Action of
controller
turned OFF.
Problem that
appears on • The boom throttle valve does not work.
machine
Related • The output to the boom throttle valve solenoid (current) can be checked in the monitoring function.

Defective boom throt- turning starting switch ON.
tle valve solenoid V09 (male) Resistance value
1
Possible Short circuit with chas- turning starting switch ON.
causes and sis ground in wiring Short circuit of wiring harness between CP06 Resistance
standard value 2 Min. 1 Mz
harness (Contact with (female) (13) and V06 (female) (2) with ground value
in normal state ground circuit) Short circuit of wiring harness between CP06 Resistance
Min. 1 Mz
bleshooting.
Pump controller 2 CP06 Control lever Voltage
3
Between (35) and (13) When Boom raise +
20 – 30 V
Swing
PC2000-8 43
Circuit diagram related to boom throttle valve solenoid
44 PC2000-8
Failure code [DWK0KA] 2-stage Relief Sol. Disc. 1

User code Failure code 2-stage Relief Sol. Disc.
Trouble
— DWK0KA (Pump controller 2 system)
Contents of
• No current flows at output to 2-stage relief solenoid circuit.
trouble
Problem that
• Travel power of work equipment is low (The main relief valve is not set in the HIGH PRESSURE
appears on
position).
machine
• Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
Related
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair,
information
be sure to turn output on. (For more information on how to turn output on/off, see troubleshooting for
failure code [DWK0KB].)

Defective 2-stage relief turning starting switch ON.
1 solenoid
(Internal disconnection)
Between (2) – (1) 20 – 60 z
harness
Wiring harness between CP06 (female) (3), (23)
Possible 2 (Disconnection in wiring Resistance Max. 1 z
– V03 (female) (2)
causes and or defective contact in
standard value connector) Wiring harness between CP06 (female) (15) –
Resistance Max. 1 z
in normal state J03
Hot short (short circuit out troubleshooting.
3 with 24V circuit) in wir-
ing harness Wiring harness between CP06 (female) (15) –
Voltage Max. 1 V
4
troller 2 CP06 (female) Resistance
Between (15) – chassis ground 20 – 60 z
PC2000-8 45
Circuit diagram related to 2-stage relief solenoid of pump controller
46 PC2000-8
Failure code [DWK0KB] 2-stage Relief Sol. S/C 1

User code Failure code 2-stage Relief Sol. S/C
Trouble
— DWK0KB (Pump controller 2 system)
Contents of
• Abnormal current flowed at output to 2-stage relief solenoid circuit.
trouble
Action of • Turns output to 2-stage relief solenoid circuit OFF.
Problem that
• Travel power of work equipment is low (The main relief valve is not set in the HIGH PRESSURE
appears on
position).
machine
Related • Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
information (Code 02300: Solenoid 1)

Defective 2-stage relief turning starting switch ON.
solenoid V08 (male) Resistance
1
Possible
causes and Ground fault in wiring a Prepare with starting switch OFF, then carry out troubleshooting without
standard value 2
in normal state (Short circuit with GND Wiring harness between CP06 (female) (15) –
a Prepare with starting switch OFF, then keep the engine running and
Defective pump con- CP06 Travel control lever Voltage
3
troller 2
Between (3) – NEUTRAL Max. 1 V
chassis ground Travel operation 20 – 30 V
Circuit diagram related to 2-stage relief solenoid of pump controller
PC2000-8 47
Failure code [DWK2KA] Back Press Comp Valve Sol Open Circuit 1
User code Failure code Back Press Comp Valve Sol Open Circuit
Trouble
— DWK2KA (Pump controller 2 system)
Contents of
• Open error was detected in the variable back pressure solenoid valve circuit.
trouble
controller • If cause of failure disappears, the system resets itself.
Problem that
• Relief pressure except that for the swing and travel sometimes deviates from the standard set pres-
appears on
sure.
machine
• The input status (ON or OFF) from the variable backpressure solenoid valve can be checked with
Related
information
(Monitoring code: 02300 Solenoid 3)

Defective variable a Prepare with starting switch OFF, then carry out troubleshooting without
back pressure solenoid turning starting switch ON.
1
harness (Disconnec- Wiring harness between CP06 (female) (3) (23)
Possible tion or defective con- – V01 (female) (2)
causes and tact in connector) Wiring harness between CP06 (female) (28) –
Resistance Max. 1 z
standard value V01 (female) (1)
out troubleshooting
Voltage Max. 1 V
Defective pump con-
4 CP06 Swing control lever Voltage
troller 2
Between (28) and At neutral Max. 1 V
chassis ground In swing operation 20 – 30 V
Circuit diagram related to back pressure compensation valve solenoid
48 PC2000-8
Failure code [DWK2KB] Back Press Comp Valve Sol Short Circuit 1
User code Failure code Back Press Comp Valve Sol Short Circuit
Trouble
— DWK2KB (Pump controller 1 system)
Contents of
• Short circuit was detected in the variable backpressure solenoid valve circuit.
trouble
Action of • Variable back pressure solenoid stops output to the circuit.
Problem that
• Relief pressure except that for the swing and travel sometimes deviates from the standard set pres-
appears on
sure.
machine
• The input status (ON or OFF) from the variable back pressure solenoid valve can be checked with
Related
information
(Monitoring code: 02302 Solenoid 3)

Defective variable a Prepare with starting switch OFF, then carry out troubleshooting without
back pressure solenoid turning starting switch ON.
1
causes and Wiring harness between CP06 (female) (3), (23)
2 harness (Contact with Resistance Max. 1 z
standard value – V01 (female) (2) and ground chassis
GND circuit)
in normal state Wiring harness between CP06 (female) (28) –
Resistance Max. 1 z
Defective pump con-
3 CP06 Swing control lever Voltage
troller 2
Between (28) and At neutral Max. 1 V
chassis ground In swing operation 20 – 30 V
Circuit diagram related to back pressure compensation valve solenoid
PC2000-8 49
SEN02101-00

© 2006 KOMATSU
All Rights Reserved
50
SEN02102-00
PC2000-8

PC2000-8 20001 and up
Failure code [DWN5KA] Fan(RAD) Pump EPC Sol Open Circuit........................................................ 3
Failure code [DWN5KB] Fan(RAD) Pump EPC Sol Short Circuit ........................................................ 5
Failure code [DWNCKA] Fan(O/C) Pump EPC Sol Open Circuit ........................................................ 6
Failure code [DWNCKB] Fan(O/C) Pump EPC Sol Short Circuit......................................................... 7
Failure code [DXAAKA] P1F EPC Sol Disc.......................................................................................... 8
Failure code [DXAAKB] P1F EPC Sol S/C......................................................................................... 10
Failure code [DXABKA] P1R Pump EPC Sol. Disc............................................................................ 12
Failure code [DXABKB] P1R Pump EPC Sol. S/C............................................................................. 14
Failure code [DXACKA] P2F Pump EPC Sol. Disc. ........................................................................... 16
Failure code [DXACKB] P2F Pump EPC Sol. S/C ............................................................................. 18
Failure code [DXADKA] P2R Pump EPC Sol. Disc............................................................................ 20
Failure code [DXADKB] P2R Pump EPC Sol. S/C............................................................................. 22
Failure code [DY2CKB] Washer Drive S/C ........................................................................................ 24
Failure code [DY20MA] Low Wiper Working Abnormality .................................................................. 26
Failure code [DY2FMA] Upper Wiper Working Abnormality............................................................... 29
PC2000-8 1
Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38) .... 32
Failure code [F@BYNR] Very High LBF CYL Exhaust Temp
Failure code [f@BYNR] Very High LBR CYL Exhaust Temp
Failure code [F@BYNS] High LBF CYL Exhaust Temp
Failure code [f@BYNS] High LBR CYL Exhaust Temp
Failure code [F@BZNR] Very High RBF CYL Exhaust Temp
Failure code [f@BZNR] Very High RBR CYL Exhaust Temp
Failure code [F@BZNS] High RBF CYL Exhaust Temp
Failure code [f@BZNS] High RBR CYL Exhaust Temp
Failure code [LA10ZL] RAD system fan pump relief pressure high error........................................... 50
Failure code [LA20ZL] O/C system pump relief pressure high error .................................................. 51
2 PC2000-8

Failure code [DWN5KA] Fan(RAD) Pump EPC Sol Open Circuit 1
User code Failure code Fan(RAD) Pump EPC Sol Open Circuit
Trouble
E11 DWN5KA (Pump controller 1 system)
Contents of
• No current flows into RAD fan pump EPC solenoid circuit.
trouble
Action of
• When the solenoid is disconnected and power is OFF, fan pump becomes max. swash plate angle.
controller
Problem that
appears on • Fan motor speed cannot be controlled.
machine
Related • Output (Current) to RAD fan pump EPC solenoid can be checked with monitoring function.
information (Code 31624: RAD fan pump EPC solenoid current)

Defective RAD fan a Prepare with starting switch OFF, then carry out troubleshooting without
pump EPC solenoid turning starting switch ON.
1
tion) Between (1) – (2) 10 – 22 z
harness
2 (Disconnection or Resistance Max. 1 z
V15 (female) (1)
Possible connector) Wiring harness between V15 (female) (2) – JC11
Resistance Max. 1 z
causes and – JC14 – CP03 (female) (13)
in normal state out troubleshooting.
Short-circuiting of wir-
Between wiring harness between CP03 (female)
ing harness Voltage Max. 1 V
3 (5) – V15 (female) (1) and grounding
(Contact with 24 V cir-
cuit) Between wiring harness between V13 (female)
(2) – JC11 – JC14 – CP03 (female) (13) and Voltage Max. 1 V
grounding
4
Between (5) – (13) 7 – 14 z
PC2000-8 3
Circuit diagram related to RAD fan pump EPC solenoid
4 PC2000-8
Failure code [DWN5KB] Fan(RAD) Pump EPC Sol Short Circuit 1

User code Failure code Fan(RAD) Pump EPC Sol Short Circuit
Trouble
E11 DWN5KB (Pump controller 1 system)
Contents of
• Abnormal current flowed in RAD fan pump EPC solenoid circuit.
trouble
Action of
• When the short circuit is detected and power is OFF, fan pump becomes max. swash plate angle.
controller
Problem that
machine
Related • Output (Current) to RAD fan pump EPC solenoid can be checked with monitoring function.
information (Code 31624: RAD fan pump EPC solenoid current)

Defective RAD fan turning starting switch ON.
pump EPC solenoid V15 (male) Resistance
1
Possible
standard value 2
Pump controller 1 C03 (female) Resistance
3
defective
Between (5) – (13) 7 – 14 z
Circuit diagram related to RAD fan pump EPC solenoid
PC2000-8 5
Failure code [DWNCKA] Fan(O/C) Pump EPC Sol Open Circuit 1

User code Failure code Fan(O/C) Pump EPC Sol Open Circuit
Trouble
E11 DWNCKA (Pump controller 1 system)
Contents of
• No current flows into O/C fan pump EPC solenoid circuit.
trouble
Action of
controller
Problem that
machine
Related • Output (Current) to O/C fan pump EPC solenoid can be checked with monitoring function.
information (Code 31623: O/C fan pump EPC solenoid current)

Defective O/C fan a Prepare with starting switch OFF, then carry out troubleshooting without
pump EPC solenoid turning starting switch ON.
1
tion) Between (1) – (2) 10 – 22 z
harness
2 (Disconnection or Resistance Max. 1 z
V16 (female) (1)
Possible connector) Wiring harness between V13 (female) (2) – JC11
Resistance Max. 1 z
causes and – JC14 – CP03 (female) (13)
Short-circuiting of wir-
Between wiring harness between CP03 (female)
ing harness Voltage Max. 1 V
3 (45) – V16 (female) (1) and grounding
(Contact with 24 V cir-
cuit) Between wiring harness between V13 (female)
(2) – JC11 – JC14 – CP03 (female) (13) and Voltage Max. 1 V
grounding
4
Between (15) – (13) 7 – 14 z
Circuit diagram related to O/C fan pump EPC solenoid
6 PC2000-8
Failure code [DWNCKB] Fan(O/C) Pump EPC Sol Short Circuit 1

User code Failure code Fan(O/C) Pump EPC Sol Short Circuit
Trouble
E11 DWNCKB (Pump controller 1 system)
Contents of
• Abnormal current flowed in O/C fan pump EPC solenoid circuit.
trouble
Action of
controller
Problem that
machine
Related • Output (Current) to O/C fan pump EPC solenoid can be checked with monitoring function.
information (Code 31623: O/C fan pump EPC solenoid current)

pump EPC solenoid V16 (male) Resistance
1
Possible
standard value 2
Pump controller 1 C03 (female) Resistance
3
defective
Between (15) – (13) 7 – 14 z
Circuit diagram related to O/C fan pump EPC solenoid
PC2000-8 7
Failure code [DXAAKA] P1F EPC Sol Disc 1

User code Failure code P1F EPC Sol Disc
Trouble
E07 DXAAKA (Pump controller 1 system)
Contents of
• When P1F pump EPC solenoid was energized, disconnection was detected in solenoid.
trouble
Action of • Turns on the protection mode (including forcibly turning on the straight travel solenoid)
controller • If cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • The swing speed is reduced.
appears on • Work equipment and travel speed is reduced.
machine • The machine deviates during travel.
• Current to energize P1F pump EPC solenoid can be checked with monitoring function. (Code:
Related
01307 P1F pump EPC current)
information

Defective P1F pump turning starting switch ON.
1 EPC solenoid (Internal
disconnection)
Between (1) – (2) 7 – 14 z
Defective emergency Emergency pump drive

A33 (male) Resistance
pump drive switch switch (pump 1)
2 Normal Max. 1 z
(pump 1) (Internal dis-
Between (3) – (2)
connection) Emergency Min. 1 Mz
Normal Max. 1 z
Possible Between (6) – (5)
causes and Emergency Min. 1 Mz
A33 (female) (3)
harness
Wiring harness between A33 (female) (2) – V11
(female) (1)
connector) Wiring harness between CP03 (female) (13) –
Resistance Max. 1 z
JC14 – A33 (female) (6)
Resistance Max. 1 z
(female) (2)
4
Between (6) – (13) 7 – 14 z
8 PC2000-8
Circuit diagram related to P1F pump EPC solenoid
PC2000-8 9
Failure code [DXAAKB] P1F EPC Sol S/C 1

User code Failure code P1F EPC Sol S/C
Trouble
E07 DXAAKB (Pump controller 1 system)
Contents of
• When P1F pump control EPC solenoid was energized, short circuit was detected in solenoid.
trouble
controller • If cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • The swing speed is reduced.
appears on • Work equipment and travel speed is reduced.
machine • The machine deviates during travel.
• Current to energize P1F pump control EPC solenoid can be checked with monitoring function.
Related
(Code: 01307 P1F pump EPC current)
information

control EPC solenoid V11 (male) Resistance
1
Between (6) – chassing ground Min. 1 Mz
pump (pump 1) drive A33 (male) Resistance
2 switch (pump 1)
switch (Internal short
Possible circuit or ground fault) Between (2), (3) – (4) Min. 1 Mz
causes and Between (2), (3) – Normal
standard value Min. 1 Mz
chassing ground
in normal state
A33 (female) (3) – chassis ground
with GND circuit)
(female) (1) – chassis ground
Defective pump con- CP03 (female) Resistance
4
troller 1
Between (6) – (13) 7 – 14 z
Between (6) – chassis ground Min. 1Mz
10 PC2000-8
PC2000-8 11
Failure code [DXABKA] P1R Pump EPC Sol. Disc. 1

User code Failure code P1R Pump EPC Sol. Disc.
Trouble
E07 DXABKA (Pump controller 1 system)
Contents of
• When P1R pump EPC solenoid was energized, disconnection was detected in solenoid.
trouble
Problem that
• Work equipment, swing speed and machine travel speed are reduced.
appears on
machine
• Current to energize P1R pump control EPC solenoid can be checked with monitoring function.
Related
(Code: 01309 P1R pump EPC current)
information

Defective P1R pump a Prepare with starting switch OFF, then carry out troubleshooting without
control EPC solenoid turning starting switch ON.
1
tion) Between (1) – (2) 7 – 14 z

pump (pump 1) drive switch (pump 1)
2 Normal Max. 1 z
switch (Internal discon-
Between (9) – (8)
nection) Emergency Min. 1 Mz
Normal Max. 1 z
A33 (female) (9)
harness
(female) (1)
in connector) Wiring harness between CP03 (female) (13) –
Resistance Max. 1 z
JC14 – A33 (female) (12)
Resistance Max. 1 z
(female) (2)
4
Between (16) – (13) 7 – 14 z
12 PC2000-8
Circuit diagram related to P1R pump EPC solenoid
PC2000-8 13
Failure code [DXABKB] P1R Pump EPC Sol. S/C 1

User code Failure code P1R Pump EPC Sol. S/C
Trouble
E07 DXABKB (Pump controller 1 system)
Contents of
• When P1R pump control EPC solenoid was energized, short circuit was detected in solenoid.
trouble
Problem that
appears on
machine
Related
information

Defective P1R pump turning starting switch ON.
1
Between (1) – chassis ground Min 1. Mz
2 switch (pump 1)
chassis ground
in normal state
with GND circuit)
4
troller 1
Between (16) – (13) 7 – 14 z
14 PC2000-8
PC2000-8 15
Failure code [DXACKA] P2F Pump EPC Sol. Disc. 1

User code Failure code P2F Pump EPC Sol. Disc.
Trouble
E07 DXACKA (Pump controller 1 system)
Contents of
• When P2F pump control EPC solenoid was energized, disconnection was detected in solenoid.
trouble
Problem that
appears on
machine
Related
information

Defective P2F pump a Prepare with starting switch OFF, then carry out troubleshooting without
1
tion) Between (1) – (2) 7 – 14 z

2 Normal Max. 1 z
Between (3) – (2)
Normal Max. 1 z
A34 (female) (3)
harness
(female) (1)
connector) Wiring harness between CP03 (female) (13) –
Resistance Max. 1 z
JC14 – A34 (female) (6)
Resistance Max. 1 z
(female) (2)
4
Between (26) – (13) 7 – 14 z
16 PC2000-8
PC2000-8 17
Failure code [DXACKB] P2F Pump EPC Sol. S/C 1

User code Failure code P2F Pump EPC Sol. S/C
Trouble
E07 DXACKB (Pump controller 1 system)
Contents of
• When P2F pump control EPC solenoid was energized, short circuit was detected in solenoid.
trouble
• Stops output to circuit.
Action of
• Turns on the protection mode (including forcibly turning on the straight travel solenoid)
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on
machine
Related
information

1
Between (6) – chassing ground Min. 1 Mz
2 switch (pump 2)
chassing ground
in normal state
with GND circuit)
4
troller 1
Between (26) – (13) 7 – 14 z
Between (26) – chassis ground Min. 1Mz
18 PC2000-8
PC2000-8 19
Failure code [DXADKA] P2R Pump EPC Sol. Disc. 1

User code Failure code P2R Pump EPC Sol. Disc.
Trouble
E07 DXADKA (Pump controller 1 system)
Contents of
• When P2R pump control EPC solenoid was energized, disconnection was detected in solenoid.
trouble
Problem that
appears on
machine
Related
information

Defective P2R pump a Prepare with starting switch OFF, then carry out troubleshooting without
1
tion) Between (1) – (2) 7 – 14 z

2 Normal Max. 1 z
Between (9) – (8)
Normal Max. 1 z
A34 (female) (9)
harness
(female) (1)
Resistance Max. 1 z
JC14 – A34 (female) (12)
Resistance Max. 1 z
(female) (2)
4
Between (36) – (13) 7 – 14 z
20 PC2000-8
PC2000-8 21
Failure code [DXADKB] P2R Pump EPC Sol. S/C 1

User code Failure code P2R Pump EPC Sol. S/C
Trouble
E07 DXADKB (Pump controller 1 system)
Contents of
• When P2R pump control EPC solenoid was energized, short circuit was detected in solenoid.
trouble
• Stops output to circuit.
Action of
• Turns on the protection mode (including forcibly turning on the straight travel solenoid)
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on
machine
Related
information

Defective P2R pump turning starting switch ON.
1
Between (1) – chassis ground Min 1. Mz
2 switch (pump 2)
chassis ground
in normal state
with GND circuit)
4
troller 1
Between (36) – (13) 7 – 14 z
22 PC2000-8
PC2000-8 23
Failure code [DY2CKB] Washer Drive S/C 1

User code Failure code Washer Drive S/C
Trouble
— DY2CKB (Pump controller 2 system)
Contents of
• Abnormal current flowed in washer drive circuit.
trouble
Action of
• Stops output to washer motor circuit.
monitor panel
Problem that
appears on • Window washer operation stops.
machine
Related
information

Defective washer turning starting switch ON.
1 motor
M06A, M06B (male) Resistance
Between (2) – (1) 5 – 40 z
Possible Wiring harnesses between CP06 (female) (17) –
Ground fault (Short cir- RW5 (female) (1) and chassis ground Resistance Min. 1 Mz
causes and
2 cuit with GND circuit)
standard value Wiring harnesses between F01 – A03 – H02 –
in wiring harness Resistance Min. 1 Mz
in normal state RW5 (female) (3) and chassis ground
Wiring harnesses between RW5 (female) (5) –
M06A, M06B (female) (1)
Defective pump con- CP06 Washer switch Voltage
3
troller 2
Between (17) – OFF Max. 1 V
chassis ground ON 20 – 30 V
24 PC2000-8
Circuit diagram related to window washer motor
PC2000-8 25
Failure code [DY20MA] Low Wiper Working Abnormality 1

User code Failure code Low Wiper Working Abnormality
Trouble
— DY20MA (Pump controller 2 system)
Contents of
• The lower wiper contact does not close in 8 or more seconds after the lower wiper is turned on.
trouble
Action of
• Turns output to wiper motor circuit OFF.
controller
Problem that
appears on • Wiper motor does not operate
machine
• If failure code [D1E9KB] or [D1EBKB] is displayed, carry out troubleshooting for it first.
Related • State of the output to the wiper motor can be checked with monitoring function.
information (Code 02308 SWITCH INPUT 5 LOWER WIPER LIMIT SWITCH, 03700 CONTROLLER OUTPUT
1 WIPER LOWER ON, WIPER LOWER BRAKE)

Monitoring code: Check that the monitoring code 02308: SWITCH INPUT
Defective lower wiper
1 5 is indicated and that the lower wiper limit switch is ON.
storage position
(If OFF, adjust the storage position to turn the switch ON.)
Defective lower wiper Replace the lower wiper Normal state is recov-
2 Defective drive relay
drive relay drive relay with the ered
upper drive relay or the Normal state is not Failure on other
upper brake relay. recovered equipment or circuit
3 Defective brake relay
brake relay drive relay with the ered
upper drive relay or the Normal state is not Failure on other equip-
upper brake relay. recovered ment or circuit
Resistance Max. 1 z
causes and relay terminal SR3
standard value Wiring harness between relay terminal SR1 –
Resistance Max. 1 z
in normal state M05B (female) (2)
Resistance Max. 1 z
M05B (female) (5)
Wiring harness between F01-10 – A03 – relay
Resistance Max. 1 z
terminal SR2
Wiring harness between relay terminal SR4 –
RW3 – JC57A – A03
4 (Disconnection or
defective contact in Wiring harness between CP06 (female) (26) –
Resistance Max. 1 z
RES3 (1)
connector)
Wiring harness between RES3 (2) and chassis
Resistance Max. 1 z
ground
Resistance Max. 1 z
relay terminal SR3
Resistance Max. 1 z
M05B (female) (4)
Resistance Max. 1 z
RES4 (female) (1)
Wiring harness between RES4 (female) (2) and
Resistance Max. 1 z
chassis ground
26 PC2000-8

a Prepare with starting switch OFF (disconnect the related connectors),
then carry out troubleshooting without turning starting switch ON.
relay terminal SR3 and chassis ground
M05B (female) (2) and chassis ground
chassis ground
5 harness (Short circuit
with GND circuit) Resistance Min. 1 Mz
chassis ground
chassis ground
RES4 (female) (1) and chassis ground
Possible Wiring harness between F01-10 – A03 – relay
causes and terminal SR2 and chassis ground
standard value a Prepare with starting switch OFF (disconnect the related connectors),
in normal state then carry out troubleshooting without turning starting switch ON.
Defective lower wiper Between M05B (male) (2) – (4) Resistance Max. 5 z
6
motor If above resistance is normal, the lower wiper motor may be defective.
The wiper motor should also be suspected when there was no position in
Troubleshooting 1 that can turn on the lower wiper limit switch.
shooting (While wiper is in operation)
CP06 Voltage
20 – 30 V (While wiper is in operation)
sis ground
Defective pump con-
7 Between (36) and chas-
troller 20 – 30 V (For 2 seconds after wiper is stopped)
sis ground
Max. 3 V 20 – 30 V
Between (20) and chas- (At a constant cycle)
sis ground (Lower limit switch: (Lower limit switch:
ON) OFF)
PC2000-8 27
Circuit diagram related to lower wiper motor
28 PC2000-8
Failure code [DY2FMA] Upper Wiper Working Abnormality 1

User code Failure code Upper Wiper Working Abnormality
Trouble
— DY2FMA (Pump controller 2 system)
Contents of
• The upper wiper contact does not close in 8 or more seconds after the upper wiper is turned on.
trouble
Action of
• Turns output to wiper motor circuit OFF.
controller
Problem that
appears on • Wiper motor does not operate.
machine
• If failure code [D1EAKB] or [D1ECKB] is displayed, carry out troubleshooting for it first.
information (Code: 02308 SWITCH INPUT 5 UPPER WIPER LIMIT SWITCH, 03700 CONTROLLER OUTPUT
1 WIPER UPPER ON, WIPER UPPER BRAKE)

• Turn the starting switch OFF once and turn it ON again.
• Monitoring code: Check that the monitoring code 02308: SWITCH
INPUT 5 is indicated and that the limit switch or proximity switch is ON.
(When both are turned ON and the upper wiper is at the storage posi-
Defective upper wiper,
tion, the proximity switch is defective. If the opposite of above was
1 proximity switch or
observed, the limit switch is defective.)
upper limit switch
• Then move the upper wiper up to the opposite position. When it stops
there, confirm the upper limit switch or the proximity switch is turned
ON. If the upper wiper does not stop at the above position, the upper
wiper motor or proximity switch is defective.
Defective upper wiper Normal state is recov-
2 Replace with the upper Defective drive relay
drive relay ered
wiper brake relay with
Normal state is not Failure on other
the upper brake relay.
recovered equipment or circuit
3 Replace with the upper Defective brake relay
Possible brake relay ered
causes and Normal state is not Failure on other
the upper drive relay.
standard value recovered equipment or circuit
Resistance Max. 1 z
relay terminal SR3
Resistance Max. 1 z
M05A (female) (4)
Resistance Max. 1 z
M05A (female) (5)
Disconnection in wiring terminal SR2 Resistance Max. 1 z
harness (Disconnec-
4 Wiring harness between relay terminal SR4 –
tion or defective con- Resistance Max. 1 z
RW1 – JC57A – A01 and chassis ground
tact in connector)
Resistance Max. 1 z
RES1 (1)
Resistance Max. 1 z
P45 (female) (B)
Wiring harness between P45 (female) (C) and
Resistance Max. 1 z
chassis ground
Wiring harness between P45 (female) (A) – F01-4 Resistance Max. 1 z
Resistance Max. 1 z
RES2 (female) (1)
PC2000-8 29

harness (Disconnec- Wiring harness between RES2 (female) (2) and
tion or defective con- chassis ground
tact in connector) Wiring harness between RES1 (female) (2) and
Resistance Max. 1 z
chassis ground
M05A (female) (2) and chassis ground
with GND circuit)
Possible Wiring harness between relay terminal SR1 –
causes and M05A (female) (4) and chassis ground
standard value Wiring harness between F01-10 – A03 – relay
terminal SR2 and chassis ground
Defective upper wiper Between M05A (male) (2) – (4) Resistance Max. 5 z
6
motor If above resistance is normal, the upper wiper motor may be defective.
Troubleshooting 1 that can turn on the upper wiper limit switch.
CP06 Voltage
Between (6) – chassis
ground
Defective pump con-
7 Between (16) and chas-
troller 20 – 30 V (For 2 seconds after wiper is stopped)
sis ground
Max. 3 V 20 – 30 V
Between (10) and chas- (At constant cycle)
sis ground (Upper limit switch: (Upper limit switch:
ON) OFF)
30 PC2000-8
Circuit diagram related to upper wiper motor
PC2000-8 31
Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED

User code Failure code High Blowby Pressure
Trouble
— F@BBZL (VHMS controller system)
Contents of • The signal circuit of the blow-by pressure sensor detected pressure of 7.06 kPa {720 mmAg} or
trouble higher.
Action of
controller
Problem that
appears on • If the machine is used as it is, the engine may be broken.
machine
• The failure codes of the VHMS system are not recorded in the failure history of the machine moni-
tor.
Related
• The 7-segment LED of the VHMS controller displays n3 o 38 (displays the code 2 characters by 2).
information
• The blow-by pressure can be checked by downloading the data to a personal computer after per-

Abnormal rise of blow-
by pressure Check the engine and repair all abnormality (including the orifice in the
1
(While system is nor- breather).
Possible mal)
causes and
Blow-by pressure sen- If failure code [DHE5KB] is displayed, perform troubleshooting for it first.
standard value 2
sor system defective If failure code [DHE5KY] is displayed, perform troubleshooting for it first.
in normal state
Prepare with starting switch OFF, then turn starting switch ON or start
VHMS controller engine and carry out troubleshooting in each case.ooting.
3
defective CV02A (female) (18) –
(13)
32 PC2000-8
Electrical diagram related to blow-by pressure sensor
PC2000-8 33
Failure code [F@BYNR] Very High LBF CYL Exhaust Temp (or change of
User code Failure code Very High LBF CYL Exhaust Temp
Trouble
— F@BYNR (VHMS controller system)
• The signal circuit of the front exhaust temperature sensor detected that the temperature had
exceeded exhaust temperature limit line 2 for 10 seconds.
Contents of
(Exhaust temperature limit line 2: The straight line connecting 750°C point in the speed range
trouble
above the rated output speed and 800°C point in the speed range below the maximum torque
speed)
Action of
controller
Problem that
machine
tor.
Related
information
• The exhaust temperature can be checked by downloading the data to a personal computer after
performing the snap shot operation.

Abnormal rise of left
front exhaust tempera-
1 Check the engine and repair all abnormality.
ture (While system is
normal)
Possible Left front exhaust tem- If failure code [DGT5KA] is displayed, perform troubleshooting for it first.
causes and 2 perature sensor sys-
standard value tem defective If failure code [DGT5KB] is displayed, perform troubleshooting for it first.
in normal state
engine and carry out troubleshooting in each case.ooting.
VHMS controller CV02A Exhaust temperature Voltage
3
defective
At 20°C Approx. 0.9 – 1.2 V
At 500°C Approx. 2.6 – 3.5 V
34 PC2000-8
Electrical diagram related to exhaust temperature sensor
PC2000-8 35
Failure code [f@BYNR] Very High LBR CYL Exhaust Temp (or change of
User code Failure code Very High LBR CYL Exhaust Temp
Trouble
— f@BYNR (VHMS controller system)
• The signal circuit of the front exhaust temperature sensor detected that the temperature had
Contents of
trouble
speed)
Action of
controller
Problem that
machine
tor.
Related • The 7-segment LED of the VHMS controller displays n3 o 72 (displays the code 2 characters by
information 2).

rear exhaust tempera-
normal)
Possible Left rear exhaust tem- If failure code [dGT5KA] is displayed, perform troubleshooting for it first.
standard value tem defective If failure code [dGT5KB] is displayed, perform troubleshooting for it first.
in normal state
3
defective
At 20°C Approx. 0.9 – 1.2 V
At 500°C Approx. 2.6 – 3.5 V
36 PC2000-8
PC2000-8 37
Failure code [F@BYNS] High LBF CYL Exhaust Temp (or change of
User code Failure code High LBF CYL Exhaust Temp
Trouble
— F@BYNS (VHMS controller system)
• The signal circuit of the left front exhaust temperature sensor detected that the temperature had
Contents of
trouble
speed)
Action of
controller
Problem that
machine
tor.
Related
information

normal)
Possible Left front exhaust tem- If failure code [DGT5KA] is displayed, perform troubleshooting for it first.
standard value tem defective If failure code [DGT5KB] is displayed, perform troubleshooting for it first.
in normal state
3
defective
At 20°C Approx. 0.9 – 1.2 V
At 500°C Approx. 2.6 – 3.5 V
38 PC2000-8
PC2000-8 39
Failure code [f@BYNS] High LBR CYL Exhaust Temp (or change of
User code Failure code High F cyl. Exhaust Temp. 1
Trouble
— f@BYNS (VHMS controller system)
• The signal circuit of the left rear exhaust temperature sensor detected that the temperature had
Contents of
trouble
speed)
Action of
controller
Problem that
machine
tor.
information 2).

normal)
Possible Left rear exhaust tem- If failure code [dGT5KA] is displayed, perform troubleshooting for it first.
standard value tem defective If failure code [dGT5KB] is displayed, perform troubleshooting for it first.
in normal state
3
defective
At 20°C Approx. 0.9 – 1.2 V
At 500°C Approx. 2.6 – 3.5 V
40 PC2000-8
PC2000-8 41
Failure code [F@BZNR] Very High RBF CYL Exhaust Temp (or change
of VHMS-LED display from n3 to 82) 1
User code Failure code High R cyl. Exhaust Temp. 2
Trouble
— F@BZNR (VHMS controller system)
• The signal circuit of the right front exhaust temperature sensor detected that the temperature had
Contents of
trouble
speed)
Action of
controller
Problem that
machine
tor.
Related
information

Abnormal rise of right
normal)
Possible Right front exhaust If failure code [DGT6KA] is displayed, perform troubleshooting for it first.
causes and 2 temperature sensor
standard value system defective If failure code [DGT6KB] is displayed, perform troubleshooting for it first.
in normal state
3
defective
At 20°C Approx. 0.9 – 1.2 V
At 500°C Approx. 2.6 – 3.5 V
42 PC2000-8
PC2000-8 43
Failure code [f@BZNR] Very High RBR CYL Exhaust Temp (or change of
User code Failure code Very High RBR CYL Exhaust Temp
Trouble
— f@BZNR (VHMS controller system)
• The signal circuit of the right rear exhaust temperature sensor detected that the temperature had
Contents of
trouble
speed)
Action of
controller
Problem that
machine
tor.
information 2).

normal)
Possible Right rear exhaust If failure code [dGT6KA] is displayed, perform troubleshooting for it first.
standard value system defective If failure code [dGT6KB] is displayed, perform troubleshooting for it first.
in normal state
3
defective
At 20°C Approx. 0.9 – 1.2 V
At 500°C Approx. 2.6 – 3.5 V
44 PC2000-8
PC2000-8 45
Failure code [F@BZNS] High RBF CYL Exhaust Temp (or change of
User code Failure code High RBF CYL Exhaust Temp
Trouble
— F@BZNS (VHMS controller system)
• The signal circuit of the right front exhaust temperature sensor detected that the temperature had
Contents of
trouble
speed)
Action of
controller
Problem that
machine
tor.
Related
information

normal)
Possible Right front exhaust If failure code [DGT6KA] is displayed, perform troubleshooting for it first.
standard value system defective If failure code [DGT6KB] is displayed, perform troubleshooting for it first.
in normal state
3
defective
At 20°C Approx. 0.9 – 1.2 V
At 500°C Approx. 2.6 – 3.5 V
46 PC2000-8
PC2000-8 47
Failure code [f@BZNS] High RBR CYL Exhaust Temp (or change of
User code Failure code High RBR CYL Exhaust Temp
Trouble
— f@BZNS (VHMS controller system)
• The signal circuit of the right rear exhaust temperature sensor detected that the temperature had
Contents of
trouble
speed)
Action of
controller
Problem that
machine
tor.
Related
information

normal)
Possible Right rear exhaust If failure code [dGT6KA] is displayed, perform troubleshooting for it first.
standard value system defective If failure code [dGT6KB] is displayed, perform troubleshooting for it first.
in normal state
3
defective
At 20°C Approx. 0.9 – 1.2 V
At 500°C Approx. 2.6 – 3.5 V
48 PC2000-8
PC2000-8 49
Failure code [LA10ZL] RAD system fan pump relief pressure high error1
User code Failure code RAD system fan pump relief pressure high error
Trouble
— LA10ZL (Pump controller 1 system)
Contents of • The RAD system fan pump pressure sensor signal circuit detected the pressure 37.3 MPa or
trouble above {380 kg/cm2 or above}.
Action of
controller
Problem that
machine
Related • Input from the RAD fan pump pressure sensor can be checked with monitoring function.
information (Code: 01133 RAD FAN PUMP PRESSURE SENSOR VOLTAGE)

Abnormal increase of
RAD fan pump pres- Check the RAD fan pump for the relief pressure. Correct, if abnormality
1
sure (When system is was found. Refer to "Testing and adjusting, Part 2."
normal)
Possible If failure code [DHPTKX] is displayed, carry out the troubleshooting first as
causes and Defective RAD fan stated.
standard value 2 pump pressure sensor
in normal state system If failure code [DA25KP] is displayed, carry out the troubleshooting first as
stated.
3
troller 1 Between CP01 (7) –
(21)
Circuit diagram related to RAD fan pump system
50 PC2000-8
Failure code [LA20ZL] O/C system pump relief pressure high error 1
User code Failure code Abnormal high-pressure of O/C system pump relief
Trouble
— LA20ZL (pump controller 1 system)
Contents of • The O/C system fan pump pressure sensor signal circuit detected the pressure 37.3 MPa or above
trouble (380 kg/cm2 or above).
Action of
controller
Problem that
machine
Related • Input from the O/C fan pump pressure sensor can be checked with monitoring function.
information Code: 01135 O/C fan pump pressure sensor voltage)

Abnormal increase of
O/C fan pump pres- Check the RAD fan pump for the relief pressure. Correct, if abnormality
1
sure (When system is was found. Refer to "Testing and adjusting, Part 2."
normal)
Possible If failure code [DHPUKX] is displayed, carry out the troubleshooting first
causes and Defective O/C fan as stated.
standard value 2 pump pressure sensor
in normal state system If failure code [DA25KP] is displayed, carry out the troubleshooting first as
stated.
3
troller 1 Between CP01 (1) –
(21)
PC2000-8 51
Circuit diagram related to O/C fan pump system
52 PC2000-8
SEN02102-00

© 2006 KOMATSU
All Rights Reserved
54
SEN02103-00
PC2000-8

PC2000-8 20001 and up
Troubleshooting of electrical system
(E-mode)
Troubleshooting of electrical system (E-mode)............................................................................................... 4
Contents of troubleshooting table......................................................................................................... 6
E-1 When starting switch is turned ON, machine monitor displays nothing ......................................... 8
E-2 When starting switch turned ON (before starting engine), basic check item lights up................. 10
E-3 Engine does not start (Engine does not turn) .............................................................................. 12
E-4 Auto-decelerator does not operate .............................................................................................. 16
E-5 Automatic warm-up system does not operate ............................................................................. 17
E-6 Preheater does not work ............................................................................................................. 18
E-7 Whole work equipment, swing operation and machine travel operation are disabled ................. 20
E-8 Machine push-up function does not work .................................................................................... 22
E-9 Boom shockless function cannot be released ............................................................................. 24
E-10 Machine monitor does not display some items.......................................................................... 26
E-11 Contents of display by machine monitor are different from applicable machine........................ 27
E-12 Fuel level monitor lights up in red while engine is running ........................................................ 28
PC2000-8 1
E-13 Hydraulic oil temperature gauge does not indicate normally ..................................................... 29
E-14 Fuel level gauge does not indicate normally.............................................................................. 30
E-15 Swing lock monitor does not indicate normally.......................................................................... 32
E-16 Machine monitor display anything even when operated on monitor switch section .................. 34
E-17 Wiper does not work .................................................................................................................. 35
E-18 Monitoring function does not display "Travel" normally ............................................................. 42
E-19 Travel alarm does not sound ..................................................................................................... 44
E-20 All of room lamp, headlamp and working lamp do not light up .................................................. 45
E-21 Air conditioner does not work .................................................................................................... 50
E-22 Step light does not light up or goes off....................................................................................... 52
2 PC2000-8
Troubleshooting of electrical system (E-mode) 1

Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power irrespective of the starting switch position).
a When carrying out troubleshooting related to a failure code, you should first check the fuse box to see if
the power is supplied normally.
Type of power supply Fuse No. Fuse capacity Destination of power

1 10A Emergency swing holding brake solenoid valve
Machine push-up switch
2 10A
Switch power supply circuit Boom damping solenoid valve
breaker (B) PPC oil pressure lock solenoid valve
3 10A
(2) (60A) Starter cut relay
(B13-B14)
4 10A Cigarette lighter
Horn
5 10A
Flash light
6 10A Bottom dump
7 10A Rotary lamp
Switch power supply circuit
breaker (B) 8 10A Auxiliary lamp
(1) (60A) 9 10A Radio
(B11-B12) Wiper
10 30A
Windshield washer
Switch power supply circuit 11 20A Air conditioner unit (upper)
breaker (B) 12 20A Air conditioner unit (lower)
(2) (60A)
(B13-B14) 13 20A 12 V power supply
14 5A Left bank engine controller (ACC) circuit
Fuse in the circuit diagram
15 5A Right bank engine controller (ACC) circuit
16 10A Radio backup
17 10A Network bus power supply
Engine controller
Constant power supply circuit
breaker (B) 18 20A Pump controller
(3) (60A) Room lamp (cab base)
(B17-B18) Room lamp (cab)
19 20A
Emergency stop circuit
20 10A Step light
* The bracket ( ) under the breaker shows a breaker terminal number
4 PC2000-8
Location of fuse
Located in the distribution board inside the cab
base.
PC2000-8 5
Contents of troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Machine Machine Names of the failure symptoms displayed in the failure history on the
Trouble
monitor monitor machine monitor
display display
Contents of
State where the machine monitor or controller detects the trouble
trouble
Action of Action to be taken to protect the system and equipment when the machine monitor or control-
controller ler detects a trouble
Problem that
Problem that appears as an abnormality in the machine by the action (above) taken by monitor
appears on
or controller
machine
Related
Information related to troubles occurred or troubleshooting
information
<Described contents>
• Standard value when normal required to judge the possible
cause
1 • Remarks required to judge whether any cause is right or not
<Symptoms of defective harness>

• Disconnection in wiring
The connector connection is defective or the wiring harness is
disconnected.
• Defective grounding
A harness not connected to GND (ground) circuit comes into
contact with the GND (ground) circuit.
• Hot short defect
2 A harness not connected to the electric power supply (24V) cir-
cuit comes into contact with the electric power supply (24V) cir-
cuit.
Cause by which a trou-
Possible ble is assumed to be • Short circuit
causes and detected A harness abnormally comes into contact with a harness of sepa-
standard value (The order number rate circuit.
in normal state indicates a serial num-
ber, not a priority <Points to remember when troubleshooting>
sequence.) (1) Method of indicating connector numbers and handling
T-adapter
For troubleshooting, insert or connect the T-adapter as
3 described below unless especially specified.
• When “male” or “female” is not indicated for a connector
number, disconnect the connector, and insert the T- adapter
in both the male and female.
• When “male” or “female” is indicated for a connector num-
ber, disconnect the connector, and insert the T-adapter in
only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads of
the tester as described below unless especially specified.
4 • Connect the plus (+) lead to a pin number or harness indi-
cated in the front.
• Connect the minus (–) lead to a pin number or harness indi-
cated in the rear.
6 PC2000-8
Related circuit diagram
This drawing is a part of the electric circuit diagram related to trouble-

shooting.
• Connector No.: Indicates (Model - Number of pins) and (Color).
• “Connector No. and pin No.“ from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the
same wiring harness.
• Arrow (io): Roughly shows the location on the machine.
PC2000-8 7
E-1 When starting switch is turned ON, machine monitor displays

nothing 1
Trouble • When starting switch turned ON, machine monitor displays nothing.
• As the starting switch of the machine monitor is turned on, following screens are displayed sequen-
tially: KOMATSU logo mark – Password input display (when a password is specified) – Work mode/
Travel speed confirmation display – Ordinary screen.
Related
• When the engine is started, the battery voltage may lower suddenly, depending on the ambient tem-
information
perature and the condition of the battery.
In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, how-
ever.

Low charge level of turning starting switch ON.
1
battery Battery voltage (2 pieces) Specific gravity of battery (1 piece)
Min. 24 V Min. 1.26
Defective circuit If the circuit breaker is shut down, the circuit probably has a grounding
2
breaker fault.
Improper connector Machine monitor connector is connected improperly. Check it directly.
3
connection (Collate the plate of the mounting bracket against the connector.)
Wiring harness between battery (–) terminal and
Resistance Max. 1 z
chassis ground
Disconnection in wiring Wiring harness between battery (+) terminal – Resistance Max. 1 z
harness B17
4 (Disconnection in wir- Wiring harness between B18 – B28A Resistance Max. 1 z
ing or defective contact Wiring harness between B28B – CM01(female)
Possible in connector) Resistance Max. 1 z
(1), (2)
causes and
standard value Wiring harness between CM01 (female) (3), (4) –
in normal state JB10 – A24 – battery (–) terminal and chassis Resistance Max. 1 z
ground
Wiring harness between B28B – H11 (female) (1) Resistance Max. 1 z
Wiring harness between battery (+) terminal –
B17 (1) and chassis ground
Between wiring harness B18 – B28A and chassis
ground
with GND circuit)
Wiring harness between B28 – CM01 (female)
(1) and (2) and chassis ground
Wiring harness between B28B – H11 (female) (1)
and chassis ground
a Prepare with starting switch OFF, then hold starting switch OFF and ON
and carry out troubleshooting in each case.
Defective machine
6 CM01 Starting switch Voltage
monitor
Between (1), (2) –
OFF 20 – 30 V
(3), (4)
8 PC2000-8
Circuit diagram related to machine monitor
PC2000-8 9
E-2 When starting switch turned ON (before starting engine), basic

check item lights up 1
Trouble (1) Radiator coolant level monitor lights up in red.
• The radiator coolant level monitor is included in the basic check items. However, it must be also
checked for abnormality while the engine is run.
Related
(This troubleshooting must be implemented when it lights up in red while the engine is run, too.)
information
• The signal from the radiator coolant level switch can be checked with monitoring function.
(Code 04500: MONITOR INPUT 1)

Lowering of radiator
1 coolant level (when Radiator coolant level may be low. Check it and add coolant if it is low.
system is normal)
Defective radiator cool- turning starting switch ON.
2 ant level sensor (inter- P24 (male) Sub-tank coolant level Resistance
nal disconnection) Between FULL – LOW Max. 1 z
Between (1) – (2)
Possible Below LOW Min. 1 Mz
standard value Disconnection in wiring turning starting switch ON.
Wiring harness between OLLV (female) (3) – P24
(female) (1)
in connector) Wiring harness between P24 (female) (2) and
Resistance Max. 1 z
chassis ground (TE04)
Defective machine
4 CM02 Sub-tank coolant level Voltage
monitor
Between (3) and chas- Between FULL – LOW Max. 1 V
sis ground Below LOW 20 – 30 V
Circuit diagram related to radiator coolant level switch
10 PC2000-8
Trouble (2) Engine oil level monitor lights up in red.

Related • Signal from the engine oil level switch signal can be checked with monitoring function.
information Code: 04501 MONITOR INPUT 2)

Lowering of engine oil
1 level (when system is Engine oil level may be low. Check it and add new oil if it is low.
normal)
Defective engine oil turning starting switch ON.
2 level sensor (internal OLLV (male) Engine oil level Resistance
disconnection) Between (1) and chas- Between H – L Max. 1 z
Possible sis ground Below L Min. 1 Mz
standard value Disconnection of wiring turning starting switch ON.
3 (Disconnection of wir- Resistance Max. 1 z
OLLV (female) (1)
in connector) Wiring harness between OLLV (female) (2) and
Resistance Max. 1 z
chassis ground (TE07)
Defective machine
4 CM02 Engine oil level Voltage
monitor
Between (2) and chas- Between H – L Max. 1 V
sis ground Below L 20 – 30 V
Circuit diagram related to engine oil level switch
PC2000-8 11
E-3 Engine does not start (Engine does not turn) 1

Trouble • Engine does not start (Engine does not turn).
Related • Following 2 systems of the starting lock mechanisms are installed on the engine starting circuit.
information (PPC clock switch and starting motor cutoff relay)

Low charge level of Battery voltage Specific gravity of battery
1
battery Min. 24 V Min. 1.26
If the circuit breaker is shut down or the fuse is blown, circuit probably has
Defective circuit ground fault.
2
breaker or fuse No. 3 If the machine monitor does not light up, carry out troubleshooting of E-1
first.
Defective starting turning starting switch ON.
switch H11 (male) Position Resistance
3
(internal disconnec-
tion) (Between B – C) OFF Min. 1 Mz
Between (1) and (4)
START Max. 1 z
Defective PPC lock turning starting switch ON.
4 switch S41 (female) Lock lever Resistance
(internal short circuit) Released Min. 1 Mz
Between (1) – (3)
Lock Max. 1 z
motor cutoff relay R05 R05 (female), R06 (male) Resistance
5 or R06
Between (1) – (2) 100 – 500 z
(internal disconnection
or short circuit) Between (3) – (5) Min. 1 Mz
Possible Between (3) – (6) Max. 1 z
causes and a Prepare with starting switch OFF, hold starting switch ON and start
standard value engine and carry out troubleshooting.
in normal state (If power supply, grounding system, power generating signal and start-
ing input are normal but the starting output is abnormal, starting motor
relay is defective.)
Starting
Defective starting Safety relay Voltage
switch
motor safety relay
6 Power supply: Between terminal B and chassis
(Internal disconnec- 20 – 30V
ground
tion or short circuit) ON
Power generating signal: Between R terminal or
Max. 12 V
ST1 (2), ST2(2) and chassis ground
Starting input: Between S terminal or ST1 (1),
20 – 30V
ST2 (1) and chassis ground
START
Starting output: Between terminal C and chassis
20 – 30V
ground
bleshooting.
(If the power supply and starting input normal but the starting motor
does not run, the starting motor is defective.)
Defective starting Starting
7 motor (Internal discon- Starting motor switch Voltage
nection or breakage) ACC
Power supply: Between terminal B and chassis
ON 20 – 30V
ground
Starting input: Between terminal C and chassis
START 20 – 30V
ground
12 PC2000-8

Defective alternator
8 Alternator Voltage
(Defective regulator)
Between r terminal R and chassis
Max. 12 V
ground
Wiring harness between B28B – H11 (female) (1) Resistance Max. 1 z
Wiring harness between H1 (female) (4) – R05
Resistance Max. 1 z
(female) (5)
Wiring harness between R05 (harness) (3) – R06
Resistance Max. 1 z
Disconnection in wiring (female) (3), (5) – ST1, ST2 (female) (1)
harness Wiring harness between safety relay C terminal –
Resistance Max. 1 z
9 (Disconnection in wir- starting motor C terminal
ing or defective contact Wiring harness between F01-3 – S41 (female)
in connector) Resistance Max. 1 z
(1)
Wiring harness between S41 (female) (3) – R05
Resistance Max. 1 z
(female) (1)
Possible Wiring harness between R05 (female) (2) and
Resistance Max. 1 z
causes and chassis ground (TB04)
standard value Wiring harness between R06 (female) (2) – P40
in normal state Resistance Max. 1 z
(male) (2) and chassis ground
Wiring harness between battery relay B terminal
– circuit breaker B28A and chassis ground
and chassis ground
Grounding fault in wir-
Wiring harness between R05 (female) (3) – R06
ing harness
10 (female) (3), (5) – ST1, ST2 (female) (1) and Resistance Min. 1 Mz
(Short circuit with
chassis ground
ground circuit)
Wiring harness between safety relay C terminal –
starting motor C terminal and chassis ground
Wiring harness between F01-3 – S41 (female)
(1) and chassis ground
Wiring harness between R06 (female) (2) – P40
PC2000-8 13

Wiring harness between battery relay B terminal
Voltage Max. 1 V
– circuit breaker B28A and chassis ground
Voltage Max. 1 V
and chassis ground
Hot short circuit in wir- (female) (5) and chassis ground Voltage Max. 1 V
Possible
ing harness
causes and 11 Wiring harness between R05 (female) (3) – R06
(Contact with 24V cir-
standard value (female) (3), (5) – ST1, ST2 (female) (1) and Voltage Max. 1 V
cuit)
in normal state chassis ground.
Wiring harness between safety relay C terminal –
Voltage Max. 1 V
starting motor C terminal and chassis ground
Wiring harness between F01-3 – S41 (female)
Voltage Max. 1 V
Voltage Max. 1 V
Defective power sup- Defective engine controller power supply is suspected. Carry out trouble-
12
ply of engine controller shooting for failure codes [CA441], [CB441], [CA442] and [CB442].
14 PC2000-8
Related electrical circuit diagram
PC2000-8 15
E-4 Auto-decelerator does not operate 1

Trouble • Auto-decelerator does not operate.
• Set speed of auto-decelerator is 1,400 rpm. Thus, the fuel control dial must be set above this speed
Related
when operating the auto-decelerator.
information
• Check all the monitoring indications after starting the engine.

If the monitoring display is not normal, proceed to troubleshooting of fail-
ure code [DHS8KX].
Defective boom raise
1 Monitoring code Item Normal display
signal
Lever operation: ON
01900 Boom Raise
Lever at neutral: OFF
ure code [DHS9KX].
Defective boom lower
signal
Lever operation: ON
01900 Boom lower
ure code [DHS3KX].
3 Defective arm IN signal Monitoring code Item Normal display
Lever operation: ON
01900 Arm IN
ure code [DHSCKX].
Defective arm dump
signal
Lever operation: ON
01900 Arm OUT
Possible
causes and ure code [DHS4KX].
standard value Defective bucket
in normal state 5 Monitoring code Item Normal display
CURL signal
Lever operation: ON
01901 Bucket Curl
ure code [DHSDKX].
Defective bucket dump
signal
Lever operation: ON
01901 Bucket dump
ure code [DHSAKX].
Defective swing right
signal
Lever operation: ON
01902 Right swing
ure code [DHSBKX].
Defective swing left
signal
Lever operation: ON
01902 Left swing
If monitoring display is not normal, proceed to troubleshooting No. E-18.
Defective R.H travel Monitoring code Item Normal display
9
signal Lever operation: ON
01902 R.H travel
16 PC2000-8

Possible
Defective L.H travel Monitoring code Item Normal display
causes and 10
signal Lever operation: ON
standard value 01902 L.H travel
in normal state Lever at neutral: OFF
Defective pump Since trouble is in system, troubleshooting cannot be carried out.
11
controller (If above causes are not detected, controller may be defective.)
E-5 Automatic warm-up system does not operate 1

Trouble • Automatic warm-up system does not operate.
• When engine coolant temperature is below 30°C, automatic warm-up system raises engine speed
Related to 1,200 rpm.
information • If fuel control dial is opened more than 70% for 3 seconds or longer when starting switch is turned
ON or after engine is started, automatic warm-up system is turned OFF.

ure code [CA144].
Possible
Defective engine cool- Monitoring Item Normal display
causes and 1
ant temperature signal Compare with
standard value Engine coolant
in normal state 04107 actual engine
temperature
coolant temperature
Defective pump Since trouble is in system, troubleshooting cannot be carried out.
2
controller (If above causes are not detected, controller may be defective.)
PC2000-8 17
E-6 Preheater does not work 1

Trouble (1) • When starting switch is turned to HEAT position, preheating monitor does not light up.
Related • Input of preheating signal (ON/OFF) can be checked with monitoring function.
information (Code: 04500 MONITOR INPUT 1)

Defective starting If preheating fails to operate (the heater does not warm up), refer to Trou-
1
switch system ble (2)
Possible harness (Disconnec- turning starting switch ON.
2
causes and tion or defective con- Wiring harness between CM01 (female) (16) –
Resistance Max. 1 z
standard value tact in connector) A01 (male) (35)
Defective machine CM01 Starting switch ACC Voltage
3
monitor
Between (16) and chas- OFF Max. 1V
sis ground HEAT 20 – 30 V
Trouble (2) • When starting switch is turned to HEAT position, preheater does not warm up.
Related
• If failure code [CA2555] or [CA2556] is displayed, carry out troubleshooting for it first.
information

1 switch (Internal discon- H11 (male) Starting switch Resistance
nection) OFF Min. 1 Mz
Between (1) – (3)
HEAT Max. 1 z
Defective heater relays
Heater relays (R15), (R16) Resistance
Possible 2 (Internal disconnec-
causes and tion) Between coil terminal R16C and
There is continuity
standard value chassis ground
in normal state Between contact terminals Min. 1 Mz
Defective air heater a Prepare with starting switch OFF, then carry out troubleshooting without
3 (Internal disconnec- turning starting switch ON.
tion). Between heater terminals Normal if conductive
harness (Disconnec-
Wiring harness between H11 (female) (3) – JC25
– heater relay terminals R16C, R15C
tive contact in
connector) Wiring harness between battery relay terminal M
Resistance Max. 1 z
– Heater relay terminals R15B, R16B
18 PC2000-8
PC2000-8 19
E-7 Whole work equipment, swing operation and machine travel

operation are disabled 1
Trouble • Whole work equipment, swing operation and machine travel operation are disabled.
Related
–
information

1 Defective fuse No. 3 If fuse is blown, circuit probably has ground fault.
switch S41 (female) Lock lever Resistance
2
(internal disconnec-
tion) Lock Min. 1 Mz
Between (1) – (2)
Released Max. 1 z
solenoid V21A and V21B (male) Resistance
3
or short circuit) Between (2) – (1) 20 – 60 z
Defective assembled- turning starting switch ON.
Possible 4 type diode D01
causes and D02 (male) Resistance
standard value Between (4) – (8) Min. 1 Mz
Disconnection in wiring Wiring harness between F01-3 outlet – S41
(male) (1)
Wiring harness between S41 (male) (2) – JB25 –
ing or defective contact Resistance Max. 1 z
in connector) V21A (female) (1), V21B (female) (1)
Wiring harness between V21A, V21B (female)
Resistance Max. 1 z
(2) and chassis ground (TB04)
Grounding fault in
Wiring harness between F01-3 outlet – S41
wiring harness Resistance Min. 1 Mz
6 (male) (1) and chassis ground
(Short circuit with
ground circuit) Wiring harness between S41 (male) (2) – JB25 –
V21A (male) (1), V21B (female) (1) and chassis Resistance Min. 1 Mz
ground
20 PC2000-8
Circuit diagram related to PPC lock solenoid
PC2000-8 21
E-8 Machine push-up function does not work 1

Trouble • Machine push-up function does not work.
Related
–
information

1 Defective fuse No.2 If fuse is blown, circuit probably has ground fault.
Defective machine
Machine push-up
2 push-up switch (Inter- S05 (male) Resistance
switch
nal disconnection)
OFF Min. 1 Mz
Between (5) – (6)
ON Max. 1 z
Defective machine turning starting switch ON.
push-up solenoid V08 (male) Resistance
3
causes and 4 type diode D04 (Inter-
standard value D02 (male) Resistance
nal short circuit)
in normal state Between (1) – (5) Min. 1 Mz
Disconnection in wiring Wiring harness between F01-2 outlet – S05
(male) (5)
tive contact of Resistance Max. 1 z
connector) V08 (female) (1)
Wiring harness between V08 (female) (2) – A05
Resistance Max. 1 z
and chassis ground (TB04)
6 ing harness (Short cir- Resistance Max. 1 z
(male) (5) and chassis ground
cuit with ground circuit)
Resistance Max. 1 z
22 PC2000-8
Circuit diagram related to machine push-up
PC2000-8 23
E-9 Boom shockless function cannot be released 1

Trouble • Boom shockless function cannot be released.
Related
–
information

1 Defective fuse No.2 If fuse is blown, circuit probably has ground fault.
Defective boom shock- turning starting switch ON.
2 less switch (internal S06 (male) Boom shockless switch Resistance
disconnection) OFF Min. 1 Mz
Between (3) – (4)
ON Max. 1 z
Defective machine turning starting switch ON.
push-up solenoid
3 V09 and V10 (male) Resistance
Between (1) – (2) 20 – 60 z
ground fault)
Possible 4 type diode D04
causes and D02 (male) Resistance
standard value Between (3) – (7) Min. 1 Mz
(female) (3)
ing or defective contact Wiring harness between S06 (female) (4) – A01
Resistance Max. 1 z
– JB3 – V09 , V10 (female) (1)
of connector)
Wiring harness between V09, V10 (female) (2)
Resistance Max. 1 z
and chassis ground
Grounding fault in wir- Wiring harness between F01-2 outlet – S06
Resistance Max. 1 z
6 ing harness (Short cir- (female) (3) and chassis ground
cuit with ground circuit) Wiring harness between S06 (female) (4) – A01
– JB3 – V09, V10 (female) (2) and chassis Resistance Max. 1 z
ground
24 PC2000-8
PC2000-8 25
E-10 Machine monitor does not display some items 1

Trouble • Machine monitor does not display some items.
• The LCD panel sometimes has black points (points which do not light) and bright points (points
Related
which do not go off) for the reason of its characteristics. If the number of the bright points and black
information
points do not exceed 10, points are not a failure or a defect.

a Turn starting switch ON and carry out troubleshooting.
Possible
Defective machine When following switches are operated, if all LCD panel lights up (entire
causes and 1
monitor (LCD panel) screen becomes white), LCD panel is normal.
standard value
in normal state • Switch operation: [4] + [F2] (Press them simultaneously)
Defective machine If cause 1 is not detected, machine monitor may be defective. (Since trou-
2
monitor (Monitor unit) ble is in system, troubleshooting cannot be carried out.)
26 PC2000-8
E-11 Contents of display by machine monitor are different from

applicable machine 1
Trouble • Contents of display by machine monitor are different from applicable machine.
Related
information

a Turn starting switch ON and carry out troubleshooting (Monitoring func-
tion)
Possible Monitoring code Normal display
Defective model code
causes and 1
signal 00200 Controller model mode PC2000-8 (1st)
standard value
in normal state If the monitoring display is not normal, proceed to troubleshooting of fail-
ure code [DA29KQ].
Defective machine If cause 1 is not detected, machine monitor may be defective. (Since trou-
2
monitor ble is in system, troubleshooting cannot be carried out.)
PC2000-8 27
E-12 Fuel level monitor lights up in red while engine is running 1

Trouble • Fuel level monitor lights up in red while engine is running.
• If fuel level gauge on the machine monitor indicates red range, fuel level monitor turns red.
Related
• Input signal (voltage) from the fuel level sensor can be checked with monitoring function.
information
(Code 04200: Fuel sensor voltage)

Low fuel level (when
1 a Add fuel.
Defective fuel level turning starting switch ON.
2 sensor (Internal dis- P21A (male) Fuel level Resistance
connection) Between (1) and chas- FULL (Upper limit) Approximately 12 z
Possible sis ground EMPTY (Lower limit) 85 – 110 z
causes and Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without
standard value harness turning starting switch ON.
in normal state 3 (Disconnection in wir-
ing or defective contact Wiring harness between CM01 (female) (9) – Resistance Max. 1 z
P21A (female) (1)
in connector)
Defective machine CM01 (female) Fuel level Resistance
4
monitor
Between (9) and FULL (Upper limit) Approximately 12 z
chassis ground EMPTY (Lower limit) 85 – 110 z
28 PC2000-8
E-13 Hydraulic oil temperature gauge does not indicate normally 1

• While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range
Trouble (C).
• While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
• If failure code [DA2RMC] or [dA2RMC] is displayed, carry out troubleshooting for those codes first.
Related
• Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring func-
information
tion (Code: 04401 Hydraulic oil temperature).

Defective hydraulic oil Hydraulic oil
temperature sensor P22 (male) Resistance
1 temperature
Between (1) – (2) 90 – 3.5 kz
tion or short circuit)
Between (1) and 10 – 100°C
Min. 1 Mz
chassis ground
harness
P22 (female) (1)
P22 (female) (2)
causes and
3 ing harness (Short cir-
cuit with ground circuit) Between wiring harness CP04 (female) (9) – P22
Hot short circuit in wir-
with 24V circuit) Between wiring harness CP04 (female) (9) – P22
Voltage Max. 1 V
Hydraulic oil
Defective pump con- Resistance
5 temperature
troller 2
Between (9) – (4) 90 – 3.5 kz
Between (9) and 10 – 100°C
Min. 1 Mz
chassis ground
PC2000-8 29
E-14 Fuel level gauge does not indicate normally 1

• While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
• While fuel level is low, fuel level gauge does not lower from green range (F).
• If failure code [DA2RMC] or [dA2RMC] is displayed, carry out troubleshooting for those codes first.
Related
• Input from the fuel level sensor (voltage) can be checked with monitoring function (Code: 04200
information
Fuel sensor voltage).

Monitoring code: Check the state of the incoming signal from the fuel level
switch from 02307 SWITCH INPUT 4.
1 Hi switch: ON
switch
When normal (When fuel tank is full) Mid switch: ON
Lo switch: ON
* If either the Mid switch or Lo switch is OFF, the full-tank indication does
not appear.
Defective fuel level turning starting switch ON.
sensor
2 P21A (male) Fuel level Resistance
or short circuit)
Possible
causes and Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without
standard value harness turning starting switch ON.
in normal state 3 (Disconnection in wir-
P21A (female) (1)
of connector)
cuit with ground circuit) Between harness CM01 (female) (9) – P21A
with 24V circuit) Between harness CM01 (female) (9) – P21A
Voltage Max. 1 V
Defective machine
6 CM01 Fuel level Resistance
monitor
Remarks: For PC 2000, shift in the fuel level up to q Relationship between the level switches and
the present time is interpolated based on fuel
the calculation done on the present value
indicated by the fuel level switch.
If any of the Hi, Mid and Lo switches
fails, above calculation is disabled.
30 PC2000-8
Circuit diagram related to fuel level switch
PC2000-8 31
E-15 Swing lock monitor does not indicate normally 1

• When swing lock switch is turned ON, swing lock monitor does not light up.
Trouble
• When swing lock switch is turned ON, swing lock monitor lights up.
Related • Input (ON/OFF) from the swing lock switch can be checked with monitoring function (Code: 04502
information Monitor input 3).

Defective swing lock turning starting switch ON.
1 switch (internal discon- S04 (male) Swing lock switch Resistance
nection or short circuit) OFF Min. 1 Mz
Between (5) – (6)
ON Max. 1 z
harness
JB1 – S04 (female) (5)
of connector) Wiring harness between S04 (female) (6) – JC33
and chassis ground (TB05)
causes and
standard value Grounding fault in wir-
cuit with ground circuit) Resistance Min. 1 Mz
JB1 – S04 (female) (5) and chassis ground
with 24V circuit) Voltage Max. 1 V
JB1 – S04 (female) (5) and chassis ground
Defective machine CM02 Swing lock switch Voltage
5
monitor
Between (5) and chas- OFF 20 – 30 V
sis ground ON Max. 1 V
32 PC2000-8
Circuit diagram related to swing lock switch
PC2000-8 33
E-16 Machine monitor display anything even when operated on monitor

switch section 1
Trouble (1) • Operating the working mode select switch fails to display working mode monitor.
Related
–
information

causes and
standard value Defective machine
1 Since trouble is in system, troubleshooting cannot be carried out.
monitor
in normal state
Trouble (2) • When auto-decelerator switch is operated, auto-decelerator monitor is not displayed.
Related
• If auto-decelerator fails to operate, proceed with troubleshooting No. E-4.
information

causes and
monitor
in normal state
Trouble (3) • When heavy lift switch is operated, heavy lift is not displayed.
Related
–
information

causes and
monitor
in normal state
Trouble (4) • When wiper switch is operated, wiper monitor is not displayed.
Related
a If wiper fails to operate, too, proceed with troubleshooting No. E-17.
information

causes and
monitor
in normal state
• When select switch is operated, adjust screen is not displayed.

Trouble (5) • When LCD monitor adjust switch is operated, adjust screen is not displayed.
• When maintenance switch is operated, maintenance item screen is not displayed.
Related
–
information

causes and
Defective machine
standard value 1 Since trouble is in system, troubleshooting cannot be carried out.
in normal state monitor
34 PC2000-8
E-17 Wiper does not work 1

Trouble • Wiper does not work. (1) Upper wiper does not work.
• If failure code [DY2FMA] is displayed, carry out troubleshooting for it first.
information Code: 02308 SWITCH INPUT 5 UPPER WIPER LIMIT SWITCH, 03700 CONTROLLER OUTPUT 1
WIPER UPPER ON, WIPER UPPER BRAKE)

• Turn the starting switch OFF once and turn it ON again.
• Monitoring code: Check that the monitoring code 02308: SWITCH
INPUT 5 is indicated and that the limit switch or proximity switch is ON.
(When both are turned ON and the upper wiper is at the storage posi-
Defective upper wiper,
tion, the proximity switch is defective. If the opposite of above was
1 proximity switch or
observed, the limit switch is defective.)
upper limit switch
• Then move the upper wiper up to the opposite position. When it stops
there, confirm the upper limit switch or the proximity switch is turned
ON. If the upper wiper does not stop at the above position, the upper
wiper motor or proximity switch is defective.
2 Replace with the upper Defective drive relay
drive relay ered
Normal state is not Failure on other
the upper brake relay.
recovered equipment or circuit
3 Replace with the upper Defective brake relay
brake relay ered
Possible wiper brake relay with
causes and Normal state is not Failure on other
the drive relay.
standard value recovered equipment or circuit
Resistance Max. 1 z
relay terminal SR3
Resistance Max. 1 z
M05A (female) (4)
Resistance Max. 1 z
M05A (female) (5)
Disconnection in wiring terminal SR2 Resistance Max. 1 z
harness (Disconnec-
4 Wiring harness between relay terminal SR4 –
tion or defective con- Resistance Max. 1 z
RW1 – JC57A – A01 and chassis ground
tact in connector)
Resistance Max. 1 z
RES1 (1)
Resistance Max. 1 z
P45 (female) (B)
Wiring harness between P45 (female) (C) and
Resistance Max. 1 z
chassis ground
Wiring harness between P45 (female) (A) – F01-4 Resistance Max. 1 z
Resistance Max. 1 z
RES2 (female) (1)
PC2000-8 35

harness (Disconnec- Wiring harness between RES2 (female) (2) and
tion or defective con- chassis ground
tact in connector) Wiring harness between RES1 (female) (2) and
Resistance Max. 1 z
chassis ground
with GND circuit)
Possible
standard value
in normal state Wiring harness between F01-10 – A03 – relay
Defective upper wiper Between M05A (male) (2) – (4) Resistance Max. 5 z
6
motor If above resistance is normal, the upper wiper motor may be defective.
Troubleshooting 1 that can turn on the upper wiper limit switch.
CP06 Voltage
Between (6) –
Defective pump chassis ground
7
controller Between (16) and
20 – 30 V (For 2 seconds after wiper is stopped)
chassis ground
Max. 3 V 20 – 30 V
Between (10) and
(At constant cycle)
chassis ground
(Upper limit switch: ON) (Upper limit switch: OFF)
36 PC2000-8
Circuit diagram related to upper wiper motor
PC2000-8 37
Trouble • Wiper does not work. (2) Lower wiper does not work.
• If failure code [DY20MA] is displayed, carry out troubleshooting for it first.
information (Code 02308 SWITCH INPUT 5 LOWER WIPER LIMIT SWITCH, 03700 CONTROLLER OUTPUT
1 WIPER LOWER ON, WIPER LOWER BRAKE)

Monitoring code: Check that the monitoring code 02308: SWITCH INPUT
Defective lower wiper
1 5 is indicated and that the lower wiper limit switch is ON.
storage position
(If OFF, adjust the storage position to turn the switch ON.)
2 Defective drive relay
drive relay drive relay with the ered
upper drive relay or the Normal state is not Failure on other
upper brake relay. recovered equipment or circuit
3 Defective brake relay
brake relay drive relay with the ered
upper drive relay or the Normal state is not Failure on other equip-
upper brake relay. recovered ment or circuit
Resistance Max. 1 z
causes and relay terminal SR3
standard value Wiring harness between relay terminal SR1 –
in normal state Resistance Max. 1 z
M05B (female) (2)
Resistance Max. 1 z
M05B (female) (5)
Resistance Max. 1 z
terminal SR2
RW3 – JC57A – A03
4 (Disconnection or
defective contact in Wiring harness between CP06 (female) (26) –
Resistance Max. 1 z
connector) RES3 (1)
Wiring harness between RES3 (2) and chassis
Resistance Max. 1 z
ground
Resistance Max. 1 z
relay terminal SR3
Resistance Max. 1 z
M05B (female) (4)
Resistance Max. 1 z
RES4 (female) (1)
Wiring harness between RES4 (female) (2) and
Resistance Max. 1 z
chassis ground
38 PC2000-8

M05B (female) (2) and chassis ground
chassis ground
5 harness (Short circuit
with GND circuit) Resistance Min. 1 Mz
chassis ground
chassis ground
RES4 (female) (1) and chassis ground
Possible
Wiring harness between F01- 10 – A03 – relay
standard value
in normal state a Prepare with starting switch OFF (disconnect the related connectors),
Defective lower wiper Between M05B (male) (2) – (4) Resistance Max. 5 z
6
motor If above resistance is normal, the lower wiper motor may be defective.
Troubleshooting 1 that can turn on the lower wiper limit switch.
CP06 Voltage
Between (26) and
Defective pump con- chassis ground
7
troller Between (36) and
20 – 30 V (For 2 seconds after wiper is stopped)
chassis ground
Min. 3 V 20 – 30 V
Between (20) and
(At constant cycle)
chassis ground
(Lower limit switch: ON) (Lower limit switch: OFF)
PC2000-8 39
Circuit diagram related to lower wiper motor
40 PC2000-8
E-18 Monitoring function does not display "Travel" normally 1

Trouble • "Travel" is not displayed normally with the machine monitoring function (special functions).
Related
• Monitoring code: 01902 Pressure switch 3
information

Defective travel PPC bleshooting.
oil pressure switch P09, P10, P11 and P12
1 Travel lever Resistance
(Internal disconnec- (male)
tion or short circuit) Neutral Min. 1 Mz
Between (1) – (2)
Forward or reverse Max. 1 z
P11, P12 (female) (1)
in connector) P09, P10 (female) (1)
Wiring harness between P09, P10, P11, P12
Resistance Max. 1 z
(female) (1) – CP04 (female) (21)
3 ing harness (Short cir- Resistance Min. 1 Mz
causes and P11, P12 (female) (2) and chassis ground
cuit with ground circuit)
P09, P10 (female) (2) and chassis ground
4 ing harness (Contact Voltage Max. 1 V
with 24V circuit)
Voltage Max. 1 V
Control connector Travel lever Voltage
Between CP06 (29) and
Neutral 20 – 30 V
chassis ground
Defective pump
5 Between CP06 (29) and
controller Forward or reverse Max. 1 V
chassis ground
Neutral 20 – 30 V
chassis ground
Forward or reverse Max. 1 V
chassis ground
42 PC2000-8
Circuit diagram related to travel PPC oil pressure switch
PC2000-8 43
E-19 Travel alarm does not sound 1

• Alarm does not sound during travel.
Trouble
• Alarm sounds in stopped state.
Related
–
information

Monitoring Item Normal display
1 Defective travel signal
01902 R.H travel Lever operation: ON
01902 L.H travel Lever at neutral: OFF
harness
M14 (female) (1)
in connector) Wiring harness between M14 (female) (2) –
Resistance Max. 1 z
Possible CP06 (female) (3), (23)
standard value Grounding fault in wir- turning starting switch ON.
in normal state 3 ing harness (Short cir-
cuit with ground circuit) Wiring harness between CP06 (female) (18) –
M14 (female) (1) and chassis ground
Since trouble is in system, troubleshooting cannot be carried out.
4 Defective travel alarm
(If above 1 – 3 and 4 are not detected, travel alarm may be defective.)
a Prepare with starting switch OFF, then travel and carry out troubleshoot-
ing.
CP06 Travel lever Voltage
Defective pump
5 Neutral Max. 1 V
controller
Between (18) and chas- In L.H forward and L.H
sis ground reverse or R.H forward 20 – 30 V
and R.H reverse
Circuit diagram related to travel alarm
44 PC2000-8
E-20 All of room lamp, headlamp and working lamp do not light up 1
Trouble (1) • All of room lamp, headlamp and working lamp do not light up.
Related
–
information

Shut down of circuit
breakers No. B21, B22 If the circuit breakers and fuses are shut down, the circuit probably has a
1
and B23 and fuses F01 grounding fault.
(3), (8) and (19)
2 Defective light switch Between S02 (female) (5) – (4), (5) – (6) Resistance
Light switch ON Max. 1 z
Light switch OFF Min. 1 Mz
Defective room lamp
3 Between S16 (female) (5) – (6) Resistance
switch
Room lamp switch ON Max. 1 z
Room lamp switch OFF Min. 1 Mz
causes and Defective fog lamp
4 Between S17 (female) (5) – (6) Resistance
standard value switch
Fog lamp switch ON Max. 1 z
in normal state
Fog lamp switch OFF Min. 1 Mz
Wiring harness between S02 (female) (5) – F01-
3
ing or defective contact Wiring harness between S16 (female) (5) – F01- Resistance Max. 1 z
in connector) 19
Resistance Max. 1 z
19
a Prepare with starting switch OFF, and then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wir- Resistance Min. 1 Mz
3 and chassis ground
cuit with ground circuit) Wiring harness between S16 (female) (5) – F01- Resistance Min. 1 Mz
PC2000-8 45
Trouble (2) • Headlamp and working lamp do not light up.

Related
–
information

Defective headlamp
The headlamp and working lamps can be defective. Check the bulbs for
1 and working lamp
burnout.
(Bulb burnout)
Wiring harness between S02 (female) (4) – D06
Resistance Max. 1 z
(female) (6)
Wiring harness between D06 (female) (2) – R08
Resistance Max. 1 z
(female) (5), R10 (female) (5), R11 (female) (5)
Wiring harness between S02 (female) (6) –
Resistance Max. 1 z
CM01 (female) (13), D06 (female) (5)
Wiring harness between circuit breaker B21B –
Resistance Max. 1 z
R11 (female) (4)
Wiring harness between circuit breaker B21C –
Resistance Max. 1 z
R11 (female) (2)
Wiring harness between circuit breaker B23B –
Resistance Max. 1 z
R08 (female) (2), (4)
Wiring harness between R08 (female) (1) – A13
(3) – L01C (female) (1), – A13 (4) – L01A Resistance Max. 1 z
(female) (1)
Possible Wiring harness between S08 (female) (3) – A13
causes and (1) – L01B (female) (1), – A13 (2) – L01D Resistance Max. 1 z
standard value Disconnection in wiring (female) (1)
in normal state harness (Disconnec-
(10) – L04B (female) (1), – A14 (11) – L04A Resistance Max. 1 z
tive contact in
(female) (1)
connector)
(8) – L04D (female) (1), – A14 (9) – L04C Resistance Max. 1 z
(female) (1)
Wiring harness between L01B (female) (2) – A13
Resistance Max. 1 z
Wiring harness between L01D (female) (2) – A13
Resistance Max. 1 z
Wiring harness between L01C (female) (2) – A13
Resistance Max. 1 z
Wiring harness between L01A (female) (2) – A13
Resistance Max. 1 z
Wiring harness between L04A (female) (2) –
Resistance Max. 1 z
chassis ground (T12) and chassis ground
Wiring harness between L04B (female) (2) –
Resistance Max. 1 z
Wiring harness between L04C (female) (2) –
Resistance Max. 1 z
Wiring harness between L04D (female) (2) –
Resistance Max. 1 z
46 PC2000-8

(1) – L01B (female) (1), – A13 (2) – L01D Resistance Min. 1 Mz
Possible
causes and Grounding fault in wir-
standard value (3) – L01C (female) (1), – A13 (4) – L01A Resistance Min. 1 Mz
in normal state cuit with ground circuit)
(10) – L04B (female) (1), – A14 (11) – L04A Resistance Min. 1 Mz
(8) – L04D (female) (1), – A14 (9) – L04C Resistance Min. 1 Mz
Trouble (3) • Room lamp does not light up.

Related
• If the headlamp and working lamp can be lit
information

Defective room lamp
1 The room lamp can be defective. Check the bulbs for burnout.
(Bulb burnout)
Possible harness
Wiring harness between S16 (female) (6) – L03
causes and 2 (Disconnection in wir- Resistance Max. 1 z
(female) (1)
standard value ing or defective contact
in normal state in connector) Wiring harness between L03 (female) (2) – JC50
Resistance Max. 1 z
– JC57A – JB66 – JB62 – chassis ground (TB04)
Prepare with starting switch OFF, then carry out troubleshooting without
Wiring harness between S16 (female) (6) – L03
PC2000-8 47
Circuit diagram relevant to room lamp, headlamp and working lamp
48 PC2000-8
E-21 Air conditioner does not work 1

Trouble (1) • Upper air conditioner does not work.
Related • For the electrical circuit inside the air-conditioner unit, refer to "Air conditioning system" in "Struc-
information ture, function and maintenance standard."

Defective fuse or cir- If fuse is blown or if circuit breaker is shut down, the circuit probably has a
1
cuit breaker grounding fault (Refer to cause 3).
harness
Wiring harness between F01-11 – M33A (female)
(3)
Possible ing or defective contact
in connector) Wiring harness between M33A (female) (2) –
chassis ground (TB14)
standard value
in normal state Grounding fault in wir- turning starting switch ON.
Wiring harness between F01-11 – M33A (female)
a Prepare with starting switch OFF, then
Defective upper air a turn starting switch ON and carry out troubleshooting.
4
conditioner unit M33A (female) Voltage
Between (3) – (2) 20 – 30 V
Trouble (2) • Lower air conditioner does not work.

Related • For the electrical circuit inside the air conditioner unit, refer to "Air conditioning system" in "Structure,
information function and maintenance standard."

Defective fuse or cir- If fuse is blown or if circuit breaker is shut down, the circuit probably has a
1
cuit breaker grounding fault (Refer to cause 3).
harness
Wiring harness between F01-12 – M33B
(female) (3)
Possible ing or defective contact
in connector) Wiring harness between M33B (female) (2) –
chassis ground (TB14)
standard value
in normal state Grounding fault in wir-
Wiring harness between F01-12 – M33B
Defective lower air out troubleshooting.
4
conditioner unit M33B (female) Voltage
Between (3) – (2) 20 – 30 V
50 PC2000-8
Circuit diagram relevant to air conditioner
PC2000-8 51
E-22 Step light does not light up or goes off 1

(1) Step light does not light up for 1 minute even
Trouble • Step light does not light up or goes off.
if the switch is pressed.
Related • If failure code [D195KA] or [D195KY] of the step light relay (R07) is displayed, carry out trouble-
information shooting for it first.

1 Defective fuse F01-20 If the fuse is blown, circuit probably has grounding fault.
Defective step light
2 The step light can be defective. Check the bulbs for burnout.
(Bulb burnout)
S13 (male) Step light switch Resistance
Released Min. 1 Mz
Between (5) – (6)
Defective step light Pressed Max. 1 z
switch or maintenance S30 (male) Step light switch Resistance
3
switch (Internal discon- OFF Min. 1 Mz
nection) Between (1) – (2)
ON Max. 1 z
Maintenance light
S30A (male) Resistance
switch
OFF Min. 1 Mz
Between (1) – (2)
ON Max. 1 z
When step light relay is replaced with another relay, if the con-
nection) R07
dition becomes normal, the relay (5-pole relay) is defective.
Possible
causes and
standard value Wiring harness between F01-20 outlet – S13
in normal state (female) (5) – R07 (female) (1), (3) – S30 Resistance Max. 1 z
(female) (1) – S30A (female) (1)
Wiring harness between S13 (female) (6) –
harness (Disconnec-
CP04 (female) (11) – S30 (female) (2) – S30A Resistance Max. 1 z
5 tion in wiring or defec- (female) (2) – CP06 (female) (14), (24)
tive contact in
connector) Wiring harness between R07 (female) (2) –
Resistance Max. 1 z
CP05 (female) (8)
Wiring harness between R07 (female) (5) – L06
Resistance Max. 1 z
(female) (1)
Wiring harness between L06 (female) (2) and
Resistance Max. 1 z
chassis ground
(female) (5) – R07 (female) (1), (3) – S30
(female) (1) – S30A (female) (1) and chassis
ground
cuit with ground circuit) Wiring harness between S13 (female) (6) –
CP04 (female) (11) – S30 (female) (2) – S30A
(female) (2) – CP06 (female) (14), (24) and chas-
sis ground
Wiring harness between R07 (female) (5) – L06
52 PC2000-8

troller (Step light switch CP04 Step light switch Voltage
Possible input system) Between (11) and Released Max. 1 V
causes and chassis ground Pressed Min. 5 V
standard value 7 a Prepare with starting switch OFF, then turn starting switch ON and carry
Defective pump con- CP05 Step light switch Voltage
troller (Step light switch
output system) Released Min. 5V
Between (8) and
Max. 1 V
chassis ground Pressed
(For 60 seconds)
PC2000-8 53
(2) Step light lights up without the switch being

Trouble • Step light does not light up or goes off
pressed.
Related
–
information

S13 (male) Step light switch Resistance
Released Min. 1 Mz
Between (5) – (6)
Defective step light Pressed Max. 1 z
switch or maintenance S30 (male) Step light switch Resistance
1
switch (Internal discon- OFF Min. 1 Mz
nection) Between (1) – (2)
ON Max. 1 z
Maintenance light
S30A (male) Resistance
switch
OFF Min. 1 Mz
Between (1) – (2)
ON Max. 1 z
When step light relay is replaced with another relay, if the con-
nection) R07
Possible dition becomes normal, the relay (5-pole relay) is defective.
causes and a Prepare with starting switch OFF, then turn starting switch ON and carry
standard value out troubleshooting.
in normal state
Wiring harness between R06 (female) (1) – R07
Hot short circuit in wir- Voltage Max. 1 V
with 24V circuit) Wiring harness between S13 (female) (6) –
CP04 (female) (11) – S30 (female) (2) – S30A
Voltage Max. 1 V
(female) (2) – CP06 (female) (14), (24) and chas-
sis ground
troller (Step light switch CP04 Step light switch Voltage
input system) Between (11) and Released Max. 1 V
chassis ground Pressed 20 – 30 V
4 a Prepare with starting switch OFF, then turn starting switch ON and carry
Defective pump con-
CP05 Step light switch Voltage
troller (Step light switch
output system) Released 20 – 30 V
Between (8) and
Max. 1 V
chassis ground Pressed
(For 60 seconds)
54 PC2000-8
Circuit diagram relevant to step light
PC2000-8 55
SEN02103-00

© 2006 KOMATSU
All Rights Reserved
56
SEN02104-00
PC2000-8

PC2000-8 20001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 3
Before troubleshooting for hydraulic and mechanical systems ............................................................ 3
Table of failure modes and causes ...................................................................................................... 8
Information in troubleshooting table ................................................................................................... 10
H-1 Speed or power of whole work equipment, travel, and swing is low ........................................... 11
H-2 Engine speed lowers remarkably or engine stalls ....................................................................... 13
H-3 Work equipment, swing, and travel mechanism do not move ..................................................... 14
H-4 Abnormal noise comes from around hydraulic pump .................................................................. 16
H-5 Speed or power of boom is low ................................................................................................... 17
H-6 Speed or power of arm is low...................................................................................................... 19
H-7 Speed or power of bucket is low ................................................................................................. 20
H-8 Boom does not move .................................................................................................................. 21
H-9 Arm does not move ..................................................................................................................... 21
H-10 Bucket does not move............................................................................................................... 21
PC2000-8 1
H-11 Hydraulic drift of work equipment is large.................................................................................. 22

H-12 Time lag of work equipment is large.......................................................................................... 23
H-13 Heavy lift function does not work or is not reset. ....................................................................... 24
H-14 Machine push-up function does not work or is not reset ........................................................... 24
H-15 Boom shockless function does not work or is not reset............................................................. 24
H-16 Machine gradually deviates during traveling ............................................................................. 26
H-17 Machine deviates excessively when started to travel................................................................ 29
H-18 Machine deviates excessively during multiple operations ......................................................... 30
H-19 Traveling speed or power is low ................................................................................................ 30
H-20 Travel system does not move (only one side) ........................................................................... 31
H-21 Upper structure does not swing................................................................................................. 32
H-22 Swing speed or acceleration is low ........................................................................................... 34
H-23 In compound operation of work equipment, swing speed or acceleration is low....................... 36
H-24 Upper structure overruns remarkably when it stops swinging ................................................... 37
H-25 Large shock is made when upper structure stops swinging ...................................................... 38
H-26 Large abnormal sound comes from when upper structure stops swinging ............................... 39
H-27 Hydraulic drift of work equipment is large in swing operation.................................................... 40
H-28 Fan rotation is abnormal (large noise or vibration of fans, or fan overheating) ......................... 41
2 PC2000-8
Troubleshooting of hydraulic and mechanical system (H-mode)1

Before troubleshooting for hydraulic and mechanical systems 1
Combination of hydraulic pumps and control valves, and hydraulic pressure measuring points
PC2000-8 3
1. Combination and operation of hydraulic 2. Troubleshooting procedure when “work

pumps equipment speed is low and machine grad-
q The work equipment, travel and swing cir- ually turns to the left during traveling”
cuit consists of two HPV375+375 tandem q Possible causes are:
pumps and two HE40 control valves for 1) Defective main relief valve of L1 or L2
port surface alignment. control valve
q The P1-F pump feeds hydraulic oil to the 2) Defective jet sensor of L1 or L2 con-
R1 control valve, the P1-R pump feeds oil trol valve
to the L1 control valve, the P2-F pump 3) Defective differential pressure sensor
feeds oil to the R2 control valve, and P2-R of L1 or L2 control valve
pump feeds oil to the L2 control valve. 4) Defective EPC solenoid valve of P1R
q The flow rate of oil from P1 and P2 pumps or P2R pump
is controlled by the EPC solenoid valve 5) Defective servo valve of P1R or P2R
that is mounted on each pump. pump
q The P1-F pump operates under NC con- 6) Defective P1R or P2R pump itself
trol. The R1 control valve has a differential q In these cases, locate the failure by mea-
pressure sensor, and the pump controller suring the relief pressure of main relief
calculates sensor signals and controls the valve, by measuring the differential pres-
EPC solenoid valve of P1-F pump by sure of jet sensor, or by measuring the
sending control signals to the valve. output voltage of differential pressure sen-
q The P1-R pump also operates under NC sor.
control. The L1 control valve has a differ- q To check the EPC solenoid valve of the
ential pressure sensor, and the pump con- pump, measure the solenoid valve output
troller calculates sensor signals and pressure.
controls the EPC solenoid valve of P1-R q To check the servo valve and the pumps,
pump by sending control signals to the remove the servo pump and perform the
valve. unit test, or measure the stroke of servo
q The P2-F pump also operates under NC pump pistons.
control. The R2 control valve has a differ- a Actual troubleshooting is carried out fol-
ential pressure sensor, and the pump con- lowing Section 4 “Troubleshooting chart
troller calculates sensor signals and when the work equipment speed is low or
controls the EPC solenoid valve of P2-F machine deviates during traveling”.
pump by sending control signals to the
valve.
q The P2-R pump also operates under NC
control. The L2 control valve has a differ-
ential pressure sensor, and the pump con-
troller calculates sensor signals and
controls the EPC solenoid valve of P2-R
pump by sending control signals to the
valve.
q The pump controller calculates signals
from each pump pressure sensor, and out-
puts control signals to the EPC solenoid
valve of each pump for equal horsepower
control and cutoff control.
q The fan driving circuit consists of a single
HPV95+95 tandem pump and two
LMF75(110) fan motors.
q The PF-F pump feeds oil to the fan motor
at the radiator side, and the PF-R pump
feeds oil to the fan motor at the oil cooler
side.
4 PC2000-8
3. Troubleshooting when “work equipment 4. Troubleshooting chart when the work

speed is low and machine gradually turns to equipment speed is low or machine devi-
the right during traveling” ates during traveling (the next page)
q Possible causes are: a Sequentially check the nature of trouble
1) Defective main relief valve of R1 or on the list, and locate the possible cause
R2 control valve indicated by the largest number of Q sym-
2) Defective jet sensor of R1 or R2 con- bols.
trol valve 1) To check the servo valve, remove the
3) Defective differential pressure sensor servo valve and perform the unit test, or
of R1 or R2 control valve measure the stroke of servo pump pis-
4) Defective EPC solenoid valve of P1F tons.
or P2F pump a The unit test of servo pump pistons
5) Defective servo valve of P1F or P2F shall be made in the authorized ser-
pump vice shop only.
6) Defective P1F or P2F pump itself 2) If the work equipment speed drops exces-
q In these cases, locate the failure by mea- sively and its pump is susceptible, check
suring the relief pressure of main relief the line filter and drain filter, too.
valve, by measuring the differential pres- 3) If the work equipment speed drops not so
sure of jet sensor, or by measuring the much but its operation is still abnormal
output voltage of differential pressure sen- after each device adjustment, check the
sor. line filter and drain filter, too.
q To check the EPC solenoid valve of the 4) Check the servo motor pistons by remov-
pump, measure the solenoid valve output ing caps from both sides and by manually
pressure. operating the pistons.
q To check the servo valve and the pumps,
remove the servo pump and perform the
unit test, or measure the stroke of servo
pump pistons.
a Actual troubleshooting is carried out fol-
lowing Section 4 “Troubleshooting chart
when the work equipment speed is low or
deviates during traveling”.
PC2000-8 5
Cause
P1R or P2R P1F or P2F L1 or L2 R1 or R2
pump pump control valve control valve
Defective differential pressure sensor
Defective differential pressure sensor

Defective EPC solenoid valve
Defective EPC solenoid valve
Defective main relief valve
Defective main relief valve

Defective servo valve
Defective servo valve

Defective pump itself
Defective pump itself
Defective jet sensor
Defective jet sensor
Right travel motor

Left travel motor
Remedy
A A A A
No.
X X X X X X X X X X X X X X
Diagnosis
The machine gradually turns to left and the work equip-
1 q q q q q q
ment speed is low.
Travel (Turn to LEFT)
The travel relief pressure of P1R or P2R pump circuit is

2 q
low.
The differential pressure of jet sensor mounted on the L1
3 q
or L2 control valve is abnormal.
The output voltage of differential pressure sensor mounted
4 q
on the L1 or L2 control valve is abnormal.
The output pressure of EPC solenoid valve mounted on
5 q
the P1R or P2R pump is abnormal.
The machine gradually turns to right and the work equip-
6 q q q q q q
ment speed is low.
The machine gradually turns to right, and the swing speed
7 q q q q q
of work equipment is very low.
Travel (Turn to RIGHT)
The machine gradually turns to right, but the swing speed

8 q
of work equipment is normal.
The travel relief pressure of P1F or P2F pump circuit is
9 q
low.
The differential pressure of jet sensor mounted on the R1
10 q
or R2 control valve is abnormal.
The output voltage of differential pressure sensor mounted
11 q
on the R1 or R2 control valve is abnormal.
The output pressure of EPC solenoid valve mounted on
12 q
the P1F or P2F pump is abnormal.
Remedy A: Adjust X: Repair or replace
6 PC2000-8
Table of failure modes and causes 1

Part that can cause failure Main pump Control valve
Self pressure reducing valve
Differential pressure sensor
Boom shockless valve

Main relief valve
Suction valve
Safety valve
Servo valve
EPC valve
PPC valve
Jet sensor
Main body
Main body
Strainer
Spool
PTO
Failure mode
Speed or power of whole work equipment, travel, and swing is
Whole work equipment
Q Q Q Q Q Q Q
low
Engine speed lowers excessively or engine stalls Q Q Q
Travel
Swing
Work equipment, swing, and travel mechanism do not move Q Q
Abnormal noise comes from around hydraulic pump Q Q
Speed or power of boom is low Q Q Q Q Q Q

Speed or power of arm is low Q Q Q Q Q
Speed or power of bucket is low Q Q Q Q Q
Boom does not move Q Q
Work equipment
Arm does not move Q Q

Bucket does not move Q Q
Hydraulic drift of work equipment is large Q Q
Time lag of work equipment is large Q
Heavy lift function does not work or is not reset Q
Machine push-up function does not work or is not reset Q Q
Boom shockless function does not work or is not reset Q
Machine deviates to the same side
Machine gradually Q Q Q Q Q Q Q Q
during forward and backward traveling
deviates during travel-
ing Machine deviates to different sides
Q Q
during forward and backward traveling
Travel
Machine deviates excessively when started to travel Q Q Q Q

Machine deviates excessively during multiple operations
Traveling speed is low or power is low Q
Travel system does not move (only one side) Q Q Q
Upper structure does To both sides
not swing To one side only Q Q Q
Swing speed or accel- To both sides
eration is low To one side only Q Q Q
In compound operation of work equipment, swing speed or
acceleration is low
Upper structure over- To both sides
Swing
runs remarkably when

it stops swinging To one side only Q Q Q
Large shock is made when upper structure stops swinging Q Q

Large abnormal sound comes from when upper structure stops
Q Q
swinging
Hydraulic drift of work When parking brake is applied
equipment is large in
swing operation When parking brake is relieved Q
Fan
Fan rotation is abnormal
8 PC2000-8
Q
Q
PPC cutoff valve
Q
Throttle shift valve
Q
Variable back pressure valve
PC2000-8
Q
Travel junction valve
Q
Q
Q
Center swivel joint
Q
Variable back pressure valve
40 Troubleshooting
Q
Swing priority valve
Q
Q
Q
2-stage main relief valve
Q
Arm throttle valve (L1)
Q
Arm throttle valve (R2)
Q
Q
Boom throttle valve (R1)
Q
Straight traveling
Solenoid valves
Q
Q
Machine push-up
Q
PPC lock
Q
Bucket Hi cancel
Q
Q
Q
Swing brake
Q
Q
Q
Q
Brake
Q
Q
Internal oil leakage
Q
Q
Q
Q
Q
Q
Safety valve
Q
Q
Q
Q
Q
Q
Suction valve
Swing motor
Q
Q
Q
Q
Q
Q
Q
Q
Main body
Q
Q
Brake
Q
Internal oil leakage
Q
Q
Q
Safety valve
Travel motor
Q
Q
Q
Main body
Q
Q
Q
Swing machinery
Q
Q
Final gear
Q
Q
Q
Q
Hydraulic cylinder
Q
Q
Engine system
Q
Fan pump
Fan motor
Diagnostic code
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
9
Q H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
SEN02104-00
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Trouble Problem that appears on machine
Related
Information related to detected trouble or troubleshooting
information
Possible 2 Possible causes of the

causes and current trouble (The <Contents of description>
standard value order number indicates • Standard value in normal state required to judge possible causes
in normal state a serial number, not a • Remarks on judgment
3 priority sequence.)
10 PC2000-8
H-1 Speed or power of whole work equipment, travel, and swing is low1
Trouble • Speed or power of whole work equipment, travel, and swing is low
• Measure the work equipment, travel, and swing speed, and make sure that all of their speed (or
power) is low.
• Make sure that abnormal sound does not come from around the hydraulic pump. (If abnormal sound
Related is heard, troubleshoot the related items.)
information • Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot
the related items.)
• Set the working mode in P-mode when troubleshooting is carried out.
• If a failure code relating to the pump control is displayed, carry out the troubleshooting for it first.

a Check the engine in Hi idle state.
Heavy lift switch and R.H. work
Engine speed
equipment control lever
1 Defective engine itself When Heavy lift switch is OFF and
1,780 ± 100 rpm
Boom raise is relieved
When Heavy lift switch is ON and
1,780 ± 100 rpm
a Prepare with engine stopped, then run engine at high idle speed and
Defective operation of Control lever Control circuit pressure
2 self pressure reducing +0.49 +5
All levers in neutral 3.24 –0.20 MPa {33 –2 kg/cm2}
valve
If the control circuit pressure is low, adjust the self pressure reducing valve
(refer to “Testing and adjusting”).
a Stop the machine engine, close valves (1) to (6) of Fig. 1, and trouble-
shoot with the engine rotating at high idle speed.
Internal oil leakage of
3 Control lever Control circuit pressure
control system devices
All levers in neutral +0.49 +5
3.24 –0.20 MPa {33 –2 kg/cm2}
Possible carry out troubleshooting.
causes and Heavy lift switch and R.H. work
Main relief pressure
standard value equipment control lever
in normal state Incorrect adjustment or When Heavy lift switch is OFF and +1.0 +10
29.4 –2.0 MPa {300 –20 kg/cm2}
4 defective operation of Boom raise is relieved
main relief valve When Heavy lift switch is ON and +1.0 +10
32.1 –2.0 MPa {327 –20 kg/cm2}
If the oil pressure does not become normal after adjustment, the main
relief valve may have malfunctioned (at low or high pressure set side).
Check the main relief valve directly.
carry out troubleshooting. (Make sure that failure causes 2 and 4 are
Defective pump EPC normal before troubleshooting.)
5 current output Control lever EPC current of the pump
(P1/P2) All levers in neutral 220 ± 60 mA
When traveled with idle turns
450/675 ± 60 mA
(the lever to the stroke end)
carry out troubleshooting. (Make sure that failure cause 5 is normal
Defective actuation of before troubleshooting.)
pump EPC solenoid Control lever EPC solenoid valve output pressure
6
valve 0.59 MPa
All levers in neutral
(P1/P2) {6 kg/cm2}
When traveled with idle turns 1.11/2.04 ± 0.39 MPa
(the lever to the stroke end) {11.3/20.8 ± 4.0 kg/cm2}
PC2000-8 11
Fig. 1 Control System Devices
12 PC2000-8
H-2 Engine speed lowers remarkably or engine stalls 1

Trouble • Engine speed lowers remarkably or engine stalls
Related • Set the working mode in P-mode when troubleshooting is carried out.
information • If a failure code relating to the pump control is displayed, carry out the troubleshooting for it first.

Defective pump EPC Control lever EPC current of the pump
1 current output
(P1/P2) All levers in neutral 220 ± 60 mA
450/675 ± 60 mA
Possible (the lever to the stroke end)
causes and a Prepare with engine stopped, then run engine at high idle speed and
standard value carry out troubleshooting. (Make sure that failure cause 1 is normal
in normal state Defective actuation of before troubleshooting.)
pump EPC solenoid Control lever EPC solenoid valve output pressure
2
valve
All levers in neutral Max. 0.59 MPa {Max. 6 kg/cm2}
(P1/P2)
When traveled with idle turns 1.11/2.04 ± 0.39 MPa
(the lever to the stroke end) {11.3/20.8 ± 4.0 kg/cm2}
If causes 1 and 2 are not the cause of the trouble, the engine itself may
3 Defective engine itself
have failed. Troubleshoot the engine (in the S-mode).
PC2000-8 13
H-3 Work equipment, swing, and travel mechanism do not move 1

Trouble • Work equipment, swing, and travel mechanism do not move
Related • Set the working mode in P-mode when troubleshooting is carried out.
information • If a failure code relating to the pump control is displayed, carry out the troubleshooting for it first.

a Prepare with the engine stopped, then carry out troubleshooting with
Internal defect of cou- the engine stopped.
1 pling (Main pump driv- Disconnect the hydraulic pressure measuring coupler of the main pump,
ing system) and rotate the crankshaft. If the oil flows out from the coupler hole, it is
normal.
Defective operation of Control lever Control circuit pressure
2 self pressure reducing +0.49 +5
Possible All levers in neutral 3.24 –0.20 MPa {33 –2 kg/cm2}
valve
causes and If the control circuit pressure is low, adjust the self pressure reducing valve
standard value (refer to “Testing and adjusting”).
in normal state
a Stop the machine engine, close valves (1) to (6) of Fig. 1, and trouble-
shoot with the engine rotating at high idle speed.
Internal oil leakage of
3 Control lever Control relief valve pressure
control system devices
+0.49 +5
All levers in neutral 3.24 –0.20 MPa {33 –2 kg/cm2}
Defective operation of carry out troubleshooting.
4 PPC lock solenoid Lock lever Solenoid valve outlet pressure
valve When relieved Min. 2.74 MPa {Min. 28 kg/cm2}
When locked 0 MPa {0 kg/cm2}
14 PC2000-8
Fig. 1 Control System Devices
PC2000-8 15
H-4 Abnormal noise comes from around hydraulic pump 1

Trouble • Abnormal noise comes from around hydraulic pump
Related
information

1 Hydraulic oil low level The hydraulic oil level may be low. Check it directly.
The piping clamps may be loose between the hydraulic tank and the oil
2 Loose piping clamps
pump. Check them directly.
Possible
causes and Clogging of hydraulic
3 The hydraulic tank strainer may be clogged. Check it directly.
tank strainer
standard value
in normal state Internal defect of
4 The hydraulic pump may have an internal defect. Check it directly.
hydraulic pump
If the failure cause cannot be identified by troubleshooting, keep the
Check for the trouble
5 hydraulic system operating for a while and check for the trouble status
status change.
change.
16 PC2000-8
H-5 Speed or power of boom is low 1

(1) Speed or power of boom is low in the normal operation
Trouble • Speed or power of boom is low
mode.
• The normal operation mode is the state when the heavy lift switch is turned OFF and the machine
push-up switch is turned OFF.
• Make sure that the other work equipment, travel and swing speed is normal. (If not, troubleshoot the
Related related items.)
information • Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot
the related items.)
• Make sure that the electric circuit related to the boom control are normal before troubleshooting.

1 right PPC valve (boom R.H. work equipment control lever PPC valve output pressure
circuit) When boom is fully raised
Min. 2.74 MPa {Min. 28 kg/cm2}
or lowered, and to the stroke end.
2 boom throttle solenoid
R.H. work equipment control lever Solenoid valve outlet pressure
valve (R1)
When boom is raised 0 MPa {0 kg/cm2}
Possible Defective operation of
The spool of boom control valve (Lo/Hi) may have malfunctioned. Check it
causes and 3 boom control valve
directly.
standard value (spool)
in normal state The safety-suction valve, mounted on the boom control valve (Lo), may
have malfunctioned. Check it directly. (If it is replaced with another work-
Defective operation of
ing circuit for troubleshooting, completely stop the oil feeding through the
4 boom control valve
hose at the machine push-up solenoid valve. As the safety-suction valve
(safety-suction valve)
has the different set pressure and structure, be sure to reset it after the
troubleshooting has completed.)
Defective boom control The main body of boom control valve (Lo/Hi) may have malfunctioned.
5
valve (main body) Check it directly.
Defective seal of boom carry out troubleshooting.
6
cylinder R.H. work equipment control lever Leakage from cylinder
Boom raise relief Max. 20 cc/min
PC2000-8 17
Trouble • Speed or power of boom is low (2) Speed or power of boom is low in Heavy lift mode
• In Heavy lift mode, the Heavy lift switch is in ON state.
related items.)
Related
• Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot
information
the related items.)
• Make sure that the electric circuit of heavy lift solenoid valve is normal before troubleshooting.

1 2-stage relief solenoid R.H. work equipment control lever Solenoid valve outlet pressure
valve At neutral 0 MPa {0 kg/cm2}
Possible When boom is raised alone Min. 2.74 MPa {Min. 28 kg/cm2}
standard value carry out troubleshooting.
in normal state
Incorrect adjustment or
2 defective operation of At neutral Main relief pressure
main relief valve +1.0 +10
When boom is raised alone 32.1 MPa {327 kg/cm2}
–2.0 –20
If the trouble continues after the adjustment, the main relief valve (at high
pressure set side) may have malfunctioned. Check it directly.
Trouble • Speed or power of boom is low (3) Speed or power of boom is low in Machine push-up mode.
• In Machine push-up mode, the Machine Push-Up switch is in ON state.
related items.)
Related
information
the related items.)
• Check the electric circuit of machine push-up solenoid valve first.

Possible Machine push-up switch Solenoid valve outlet pressure
1 machine push-up sole-
causes and
noid valve OFF Min. 2.74 MPa {Min. 28 kg/cm2}
standard value
in normal state ON 0 MPa {0 kg/cm2}
Defective operation of The safety-suction valve mounted on the boom control valve (Lo) may
2 boom control valve have malfunctioned (at the high pressure set side of the head). Check it
(safety-suction valve) directly.
18 PC2000-8
H-6 Speed or power of arm is low 1

Trouble • Speed or power of arm is low
related items.)
Related • Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot
information the related items.)
• Make sure that the electric circuit of arm control parts is normal before troubleshooting.

1 left PPC valve (arm cir-
L.H. work equipment control lever PPC valve output pressure
cuit)
During arm IN or OUT in full stroke Min. 2.74 MPa {Min. 28 kg/cm2}
2 arm throttle solenoid
L.H. work equipment control lever Solenoid valve outlet pressure
valve (L1 or R2)
During arm IN or OUT operation 0 MPa {0 kg/cm2}
The spool of arm control valve (Lo/Hi) may have malfunctioned. Check it
causes and 3 arm control valve
directly.
in normal state Defective operation of The safety-suction valve, mounted on the arm control valve (Lo/Hi), may
safety-suction valve have malfunctioned. Check it directly. (If it is replaced with another work-
4
mounted on the arm ing circuit for troubleshooting, be sure to reset the safety-suction valve
control valve (Lo) after the troubleshooting because the valve has the different set pressure.)
The main body of arm control valve (Lo/Hi) may have malfunctioned.
5 arm control valve
Check it directly.
(main body)
Defective seal of arm carry out troubleshooting.
6
cylinder L.H. work equipment control lever Leakage from cylinder
Arm IN relief Max. 20 cc/min
PC2000-8 19
H-7 Speed or power of bucket is low 1

Trouble • Speed or power of bucket is low
related items.)
• Make sure that the electric circuit of bucket control parts is normal before troubleshooting.

1 right PPC valve R.H. work equipment control lever PPC valve output pressure
(bucket circuit) During bucket curl or dump in full
stroke
2 bucket “Hi” cancel
solenoid valve
During bucket curl Min. 2.74 MPa {Min. 28 kg/cm2}
The spool of bucket control valve (Lo/Hi) may have malfunctioned. Check
causes and 3 bucket control valve
it directly.
in normal state The safety-suction valve, mounted on the bucket control valve (Lo/Hi),
may have malfunctioned. Check it directly. (If it is replaced with another
safety-suction valve
4 working circuit for troubleshooting, be sure to reset the safety-suction
mounted on the bucket
valve after the troubleshooting because the valve has the different set
control valve
pressure.)
The main body of bucket control valve (Lo/Hi) may have malfunctioned.
5 bucket control valve
Check it directly.
(main body)
Defective seal of carry out troubleshooting.
6
bucket cylinder R.H. work equipment control lever Leakage from cylinder
Bucket curl relief Max. 20 cc/min
20 PC2000-8
H-8 Boom does not move 1

Trouble • Boom does not move
Related
related items.)
information

Possible
1 right PPC valve (boom R.H. work equipment control lever PPC valve output pressure
causes and
circuit) When boom is fully raised or low-
standard value Min. 2.74 MPa {Min. 28 kg/cm2}
in normal state ered
The spool of boom control valve (Lo/Hi) may have malfunctioned. Check it
directly.
(spool)
H-9 Arm does not move 1

Trouble • Arm does not move
Related
related items.)
information

Possible
1 left PPC valve (arm cir-
causes and L.H. work equipment control lever PPC valve output pressure
cuit)
standard value During arm IN or OUT in full stroke Min. 2.74 MPa {Min. 28 kg/cm2}
in normal state
The spool of arm control valve (Lo/Hi) may have malfunctioned. Check it
2 arm control valve
directly.
(spool)
H-10 Bucket does not move 1

Trouble • Bucket does not move
Related
related items.)
information

Possible
1 right PPC valve R.H. work equipment control lever PPC valve output pressure
causes and
(bucket circuit) During bucket curl or dump in full
standard value Min. 2.74 MPa {Min. 28 kg/cm2}
in normal state stroke
The spool of bucket control valve (Lo/Hi) may have malfunctioned. Check
it directly.
(spool)
PC2000-8 21
H-11 Hydraulic drift of work equipment is large. 1

Trouble • Hydraulic drift of work equipment is large. (1) Hydraulic drift of boom is large
Related
information

Defective seal of boom The spool of boom control valve (Lo) may have a defective seal. Check it
1
control valve (spool) directly.
The safety-suction valve (at bottom side), mounted on the boom control
Possible Defective operation of valve (Lo), may have malfunctioned. Check it directly. (If it is replaced with
causes and 2 boom control valve another working circuit for troubleshooting, be sure to reset the safety-suc-
standard value (safety-suction valve) tion valve after the troubleshooting because the valve has the different set
in normal state pressure.)
Defective seal of boom carry out troubleshooting.
3
cylinder R.H. work equipment control lever Leakage from cylinder
Boom raise relief Max. 20 cc/min
Trouble • Hydraulic drift of work equipment is large. (2) Hydraulic drift of arm is large
Related
information

Defective seal of arm The spool of arm control valve (Lo) may have a defective seal. Check it
1
control valve (spool) directly.
The safety-suction valve (at head side), mounted on the arm control valve
Possible Defective operation of (Lo), may have malfunctioned. Check it directly. (If it is replaced with
causes and 2 arm control valve another working circuit for troubleshooting, be sure to reset the safety-suc-
standard value (safety-suction valve) tion valve after the troubleshooting because the valve has the different set
in normal state pressure.)
Defective seal of arm carry out troubleshooting.
3
cylinder L.H. work equipment control lever Leakage from cylinder
Arm IN relief Max. 20 cc/min
Trouble • Hydraulic drift of work equipment is large. (3) Hydraulic drift of bucket is large
Related
information

Defective seal of
The spool of bucket control valve (Lo/Hi) may have a defective seal.
Check it directly.
(spool)
The safety-suction valve (at bottom side), mounted on the bucket control
Possible Defective operation of valve (Lo/Hi), may have malfunctioned. Check it directly. (If it is replaced
causes and
2 bucket control valve with another working circuit for troubleshooting, be sure to reset the
standard value
(safety-suction valve) safety-suction valve after the troubleshooting because the valve has the
in normal state different set pressure.)
Defective seal of carry out troubleshooting.
3
bucket cylinder R.H. work equipment control lever Leakage from cylinder
Bucket curl relief Max. 20 cc/min
22 PC2000-8
H-12 Time lag of work equipment is large 1

Trouble • Time lag of work equipment is large (1) Time lag of work equipment is large
Related
information

The safety-suction valve, mounted on the boom control valve (Lo), may
Possible
causes and have malfunctioned. Check it directly. (If it is replaced with another work-
standard value ing circuit for troubleshooting, completely stop the oil feeding through the
hose at the machine push-up solenoid valve. As the safety-suction valve
in normal state (safety-suction valve)
has the different set pressure and structure, be sure to reset it after the
troubleshooting has completed.)
Trouble • Time lag of work equipment is large (2) Time lag of arm operation is large
Related
information

Possible
The safety-suction valve, mounted on the arm control valve (Lo/Hi), may
causes and Defective operation of
standard value have malfunctioned. Check it directly. (If it is replaced with another work-
1 arm control valve
in normal state ing circuit for troubleshooting, be sure to reset the safety-suction valve
(safety-suction valve)
after the troubleshooting because the valve has the different set pressure.)
Trouble • Time lag of work equipment is large (3) Time lag of bucket operation is large
Related
information

Possible The safety-suction valve, mounted on the bucket control valve (Lo/Hi),
causes and Defective operation of may have malfunctioned. Check it directly. (If it is replaced with another
standard value 1 bucket control valve working circuit for troubleshooting, be sure to reset the safety-suction
in normal state (safety-suction valve) valve after the troubleshooting because the valve has the different set
pressure.)
PC2000-8 23
H-13 Heavy lift function does not work or is not reset. 1

Trouble • Heavy lift function does not work or is not reset.
Related
information

causes and
standard value 1 Troubleshoot by following Paragraph (2) "H-5 Speed or power of boom is low".
in normal state
H-14 Machine push-up function does not work or is not reset 1

Trouble • Machine push-up function does not work or is not reset
Related
information

causes and
standard value 1 Troubleshoot by following Paragraph (3) "H-5 Speed or power of boom is low".
in normal state
H-15 Boom shockless function does not work or is not reset 1

Trouble • Boom shockless function does not work or is not reset
Related
information

Possible Defective operation of out troubleshooting
causes and 1 boom shockless sole- Remove the solenoid valve from the valve assembly, plug its cable con-
standard value noid valve nectors into sockets, and make sure that the spool operates normally
in normal state when the boom shockless control switch is operated.
2 The boom shockless valve may have malfunctioned. Check it directly.
boom shockless valve
24 PC2000-8
H-16 Machine gradually deviates during traveling 1

Trouble • Machine gradually deviates during traveling
Related • Make sure that the travel speed is normal. (If not, troubleshoot the related items.)
information • Set the working mode in P-mode when troubleshooting is carried out.

Defective adjustment Refer to “Testing and adjusting the travel deviation” of the Testing and
1
of main pump adjusting section.
2 Travel lever PPC valve output pressure
travel PPC valve
During forward or reverse traveling
in full stroke
3 travel control valve The travel control valve (spool) may have malfunctioned. Check it directly.
(spool)
The travel control valve (main body) may have malfunctioned. Check it
4 travel control valve
directly.
(main body)
Possible Output pressure of travel PPC shut-
5 travel PPC shuttle Travel lever
causes and tle valve
valve
standard value During forward or reverse traveling
in normal state in full stroke
6 The travel junction valve may have malfunctioned. Check it directly.
travel junction valve
Defective seal of cen- Travel lever Leakage from swivel joint
7
ter swivel joint
When relieved at one side Max. 100 cc/min
If the seal is detective, the machine deviates as in the Figure 2.
Internal leakage of carry out troubleshooting.
8
travel motor Travel lever Leakage from travel motor
When relieved at one side Max. 30 l/min
Defective travel motor
9 The travel motor may have malfunctioned. Check it directly.
(main body)
The final drive may have an internal defect. Check it directly. (It may be
Internal defect of final
10 checked by abnormal sound, abnormal heating, metal powders in drain oil,
drive
etc.)
26 PC2000-8
Fig. 2 Defective sealing position of center swivel joint and machine deviation directions
PC2000-8 27
(2) Machine deviates to different sides during for-

Trouble • Machine gradually deviates during traveling
ward and backward traveling
Related • Make sure that the travel speed is normal. (If not, troubleshoot the related items.)

travel PPC valve
in full stroke
(spool)
Possible
standard value carry out troubleshooting.
Defective seal of cen- Travel lever Leakage from swivel joint
in normal state 3
ter swivel joint
If the seal is detective, the machine deviates as in the Figure 2.
Drop of travel motor
safety valve setting Travel lever Travel relief pressure
4
pressure +1.0
32.9/33.8 –2.0 MPa
(P1/P2) When relieved at one side
+10
{335/345 –20 kg/cm2}
Fig. 2 Defective sealing position of center swivel joint and machine deviation directions
28 PC2000-8
H-17 Machine deviates excessively when started to travel 1

• Machine deviates excessively when (1) Machine deviates excessively during startup only when
Trouble
started to travel the travel lever is shifted to its full-stroke position.
• Make sure that the machine does not deviate during regular traveling. (If it deviates, troubleshoot
Related
the related items.)
information

Defective operation of The main pump servo valve may have malfunctioned. Check it directly.
1
main pump servo valve (Use the separate unit test or measure the pump stroke for judgment.)
Possible (spool)
causes and
standard value
Defective seal of cen- carry out troubleshooting.
in normal state 3
ter swivel joint Travel lever Leakage from swivel joint
Internal defect of travel
The travel motor (main body) may have an internal defect. Check it
4 motor (motor main
directly.
body)
• Machine deviates excessively when started to (2) Machine deviates excessively regardless of
Trouble
travel the stroke control of travel lever
• Make sure that the machine does not deviate during regular traveling. (If it deviates, troubleshoot
Related
the related items.)
information

carry out troubleshooting. (Make sure that failure cause 3 is normal
before troubleshooting.)
Output voltage of differential pres-
1 differential pressure Travel lever
sure sensor
sensor (jet sensor)
At neutral Min. 2.77 V
Max. 1.40 V
Possible (the lever to the stroke end)
causes and Defective operation of The main pump servo valve may have malfunctioned. Check it directly.
2
standard value main pump servo valve (Use the separate unit test or measure the pump stroke for judgment.)
in normal state a Prepare with engine stopped, then run engine at high idle speed and
Travel lever Differential pressure of jet sensor
Defective adjustment Min. 1.28 MPa
At neutral
3 or defective operation {Min. 13.1 kg/cm2}
of jet sensor During traveling by one side in full Max. 0.17 MPa
stroke (Travel with idle turns) {Max. 1.7 kg/cm2}
If oil pressure does not become normal after adjustment, the relief valve
may have malfunctioned or the orifice is defective. Check them directly.
PC2000-8 29
H-18 Machine deviates excessively during multiple operations 1

Trouble • Machine deviates excessively during multiple operations
Related
the related items.)
information

Defective operation of Control lever Solenoid valve outlet pressure
Possible
1 straight traveling sole-
causes and All levers in neutral 0 MPa {0 kg/cm2}
noid valve
standard value During traveling and operation or
in normal state Min. 2.74 MPa {Min. 28 kg/cm2}
swing of work equipment
The PPC cutoff valve (for straight traveling) may have malfunctioned.
2 PPC cutoff valve (for
Check it directly.
straight traveling)
H-19 Traveling speed or power is low 1

Trouble • Traveling speed or power is low
• Make sure that the work equipment and swing speed is normal.

travel PPC valve
in full stroke
Possible 2 2-stage relief solenoid Travel lever Solenoid valve outlet pressure
causes and valve At neutral 0 MPa {0 kg/cm2}
standard value
Operated Min. 2.74 MPa {Min. 28 kg/cm2}
in normal state
Defective adjustment Travel lever Travel relief pressure
or defective operation +1.0
3 32.9/33.8 –2.0 MPa
of main relief valve When relieved at one side
+10
(P1/P2) {335/345 –20 kg/cm2}
If the trouble continues after the adjustment, the main relief valve (at high
pressure set side) may have malfunctioned. Check it directly.
30 PC2000-8
H-20 Travel system does not move (only one side) 1

(1) Both the forward and backward travel sys-
Trouble • Travel system does not move (only one side)
tems do not operate
Related
information

The travel motor (parking brake) may have malfunctioned. Check it
1 travel motor (parking
directly.
Possible brake)
standard value 2 travel motor (motor The main body of travel motor may have malfunctioned. Check it directly.
in normal state main body)
The final drive may have an internal defect. Check it directly. (It may be
Internal defect of final
3 checked by abnormal sound, abnormal heating, metal powders in drain oil,
drive
etc.)
(2) Forward or backward traveling system does

Trouble • Travel system does not move (only one side)
not operate
Related
information

travel PPC valve
in full stroke
(spool)
Possible The suction valve mounted on the travel valve may have malfunctioned.
causes and Defective travel control
3 Check it directly. (The suspect valve can be replaced with the normal suc-
standard value valve (suction valve)
tion valve and used for troubleshooting.)
in normal state
travel motor (safety Travel lever Travel relief pressure
4
valve) +1.0
32.9/33.8 –2.0 MPa
(P1/P2) When relieved at one side (in non-
moving direction) +10
{335/345 –20 kg/cm2}
The counterbalance valve of travel motor may have malfunctioned. Check
5 travel motor (counter-
it directly.
balance valve)
PC2000-8 31
H-21 Upper structure does not swing 1

(1) Upper structure does not swing in both direc-
Trouble • Upper structure does not swing
tions.
• Make sure that the work equipment operates normally and the machine travels normally. (If not,
Related troubleshoot the related items.)
information • Set the working mode in P-mode and the swing lock switch in OFF state when troubleshooting is
carried out.

Defective operation of L.H. work equipment control lever Solenoid valve outlet pressure
1 swing holding brake When in neutral
solenoid valve 0 MPa {0 kg/cm2}
(min. 10 sec elapsed)
In swing operation
(in the right or left direction)
2 swing motor (swing The swing motor (swing brake) may have malfunctioned. Check it directly.
brake)
Possible a Prepare with engine stopped, then run engine at high idle speed and
causes and carry out troubleshooting.
standard value
Incorrect adjustment or L.H. work equipment control lever Swing relief pressure
in normal state
defective operation of +1.0
3 Swing relief 29.4 –2.0 MPa
swing motor (safety
valve) (in either right or left direction) +10
{300 –20 kg/cm2}
If oil pressure does not become normal after adjustment, the safety valve
may have malfunctioned. Check it directly.
Internal defect of swing
4 motor (motor main The swing motor may have an internal defect. Check it directly.
body)
The swing machinery may have an internal defect. Check it directly. (It
5 may be checked by abnormal sound, abnormal heating, metal powders in
machinery
drain oil, etc.)
32 PC2000-8
(2) Upper structure does not swing in either

Trouble • Upper structure does not swing
direction only.
carried out.

1 left PPC valve (swing L.H. work equipment control lever PPC valve output pressure
circuit) During right or left swinging in full
stroke
Possible 2 swing control valve The swing control valve (spool) may have malfunctioned. Check it directly.
causes and (spool)
standard value Defective operation of The swing control valve (suction valve) may have malfunctioned. Check it
in normal state 3 swing control valve directly. (The right and left valves can be replaced and used for trouble-
(suction valve) shooting.)
Defective operation of The swing motor (suction valve) may have malfunctioned. Check it
4 swing motor (suction directly. (The right and left parts can be replaced and used for trouble-
valve) shooting.)
The swing motor (check valve) may have malfunctioned. Check it directly.
5 swing motor (check
(The right and left parts can be replaced and used for troubleshooting.)
valve)
PC2000-8 33
H-22 Swing speed or acceleration is low 1

(1) Swing speed or acceleration is low in both
Trouble • Swing speed or acceleration is low
right and left directions
carried out.

Internal leakage of
1 L.H. work equipment control lever Leakage from swing motor
swing motor
Swing relief
Max. 10 l/min
(in either right or left direction)
brake)
Possible carry out troubleshooting.
causes and L.H. work equipment control lever Swing relief pressure
standard value Defective adjustment
in normal state 3 Swing relief 29.4 –2.0 MPa
of swing motor (safety
{300 –20 kg/cm2}
The main body of swing motor may have an internal defect. Check it
4 motor (motor main
directly.
body)
machinery
drain oil, etc.)
34 PC2000-8
(2) Swing speed or acceleration is low in either

Trouble • Swing speed or acceleration is low
direction only.
carried out.

stroke
causes and (spool)
valve) shooting.)
valve)
PC2000-8 35
H-23 In compound operation of work equipment, swing speed or

acceleration is low 1
(1) The swing speed or acceleration is low during
• In compound operation of work equipment, swing
Trouble multiple operations such as swinging and
speed or acceleration is low
boom raise operations.
Related
information

1 boom throttle solenoid Control lever Solenoid valve outlet pressure
valve (R1) At neutral 0 MPa {0 kg/cm2}
During swinging and boom raising Min. 2.74 MPa {Min. 28 kg/cm2}
standard value Defective operation of Output pressure of boom throttle
in normal state 2 boom throttle selector Control lever
selector valve (R1)
valve (R1)
At neutral 0 MPa {0 kg/cm2}
During swinging and boom raising Same as the main pump pressure
throttle valve mounted The throttle valve mounted on the boom control valve (R1) may have mal-
3
on the boom control functioned. Check it directly.
valve (R1)
(2) The swing speed or acceleration is low during

• In compound operation of work equipment, swing
Trouble multiple operations such as swinging and
speed or acceleration is low
arm or bucket operation.
Related • Make sure that item (1) is normal first before troubleshooting.

Defective operation of Control lever Solenoid valve outlet pressure
Possible
1 swing priority solenoid
causes and At neutral 0 MPa {0 kg/cm2}
valve
standard value During swinging and during excava-
in normal state Min. 2.74 MPa {Min. 28 kg/cm2}
tion or dump by arm or bucket
The PPC cutoff valve (for swing priority) may have malfunctioned. Check it
3 PPC cutoff valve (for
directly.
swing priority valve)
36 PC2000-8
H-24 Upper structure overruns remarkably when it stops swinging 1

• Upper structure overruns remarkably when it (1) Upper structure overruns remarkably when it
Trouble
stops swinging stops swinging in both directions.
Related
information

Defective adjustment L.H. work equipment control lever Swing relief pressure
Possible of swing motor (safety
(in either right or left direction) +10
causes and valve) {300 –20 kg/cm2}
standard value If oil pressure does not become normal after adjustment, the safety valve
in normal state may have malfunctioned. Check it directly.
Internal leakage of
2 L.H. work equipment control lever Leakage from swing motor
swing motor
Swing relief
Max. 10 l/min
(in either right or left direction)
• Upper structure overruns remarkably when it (2) Upper structure overruns remarkably when
Trouble
stops swinging stopped from swinging in either direction only.
Related
information

stroke
causes and (spool)
valve) shooting.)
valve)
PC2000-8 37
H-25 Large shock is made when upper structure stops swinging 1

(1) Large shock is made when upper structure
• Large shock is made when upper structure stops
Trouble stops swinging in both right and left direc-
swinging
tions.
Related • Set the working mode in P-mode and the swing lock switch in OFF state when troubleshooting is
information carried out.

solenoid valve 0 MPa {0 kg/cm2}
In swing operation
brake)
standard value
in normal state
{300 –20 kg/cm2}
4 motor (motor main The swing motor may have an internal defect. Check it directly.
body)
machinery
drain oil, etc.)
• Large shock is made when upper structure stops (2) Large shock is made when upper structure
Trouble
swinging stops swinging in either direction only.
Related • Set the working mode in P-mode and the swing lock switch in OFF state when troubleshooting is
information carried out.

Defective operation of L.H. work equipment control lever PPC valve output pressure
1 left PPC valve (swing
circuit) At neutral 0 MPa {0 kg/cm2}
Possible
causes and During right or left swinging in full
standard value stroke
in normal state Defective operation of
2 swing control valve The swing control valve (spool) may have malfunctioned. Check it directly.
(spool)
valve) shooting.)
38 PC2000-8
H-26 Large abnormal sound comes from when upper structure stops
swinging 1
(1) Large abnormal sound comes from when
• Large abnormal sound comes from when upper
Trouble upper structure is stopped from swinging in
structure stops swinging
both right and left directions.
Related
information

L.H. work equipment control lever Solenoid valve outlet pressure
When in neutral
1 variable back pressure Min. 2.74 MPa {Min. 28 kg/cm2}
solenoid valve
In swing operation 0 MPa {0 kg/cm2}
When shifted from swing to neutral
0 MPa {0 kg/cm2}
position (for 5 sec)
Possible The variable back pressure valve may have malfunctioned. Check it
2 variable back pressure
causes and directly.
solenoid valve
standard value
in normal state
{300 –20 kg/cm2}
machinery
drain oil, etc.)
(2) Large abnormal sound comes from when

• Large abnormal sound comes from when upper
Trouble upper structure is stopped from swinging in
structure stops swinging
either direction only.
Related
information

Possible The swing control valve (spool) may have malfunctioned. Check it directly.
1 swing control valve
causes and (The right and left parts can be replaced and used for troubleshooting.)
(spool)
standard value
in normal state Defective operation of The swing motor (suction valve) may have malfunctioned. Check it
valve) shooting.)
PC2000-8 39
H-27 Hydraulic drift of work equipment is large in swing operation 1

• Hydraulic drift of work equipment is large in swing
Trouble (1) When swing brake is applied
operation
Related
information

Possible
causes and 0 MPa {0 kg/cm2}
solenoid valve (min. 12 sec elapsed)
standard value
in normal state In swing operation
brake)
• Hydraulic drift of work equipment is large in swing

Trouble (2) When swing brake is released
operation
Related
information

1 swing control valve The swing control valve (spool) may have malfunctioned. Check it directly.
(spool)
The swing control valve (suction valve) may have malfunctioned. Check it
2 swing control valve
directly.
Possible (suction valve)
standard value 3 swing motor (safety The swing motor (safety valve) may have malfunctioned. Check it directly.
in normal state valve)
valve) shooting.)
valve)
40 PC2000-8
H-28 Fan rotation is abnormal (large noise or vibration of fans, or fan

overheating) 1
Trouble • Fan rotation is abnormal (large noise or vibration of fans, or fan overheating)
• Measure the fan rotation speed and check for an error from the permissible value.
Related
• Set the working mode in P-mode and the fan in 100% speed mode when troubleshooting is carried
information
out.

a Check the engine in Hi idle state.
Defective fan pump Control lever EPC current of fan pump
EPC current output Radiator side: 625/555 ± 50 mA
1
Standard/+55°C speci- (at 840/1,100 rpm)
fications All levers in neutral
O/C side: 650/555 ± 50 mA
Possible (at 760/1,100 rpm)
causes and a Check the engine in Hi idle state.
standard value Defective operation of EPC solenoid valve output pressure
in normal state Control lever
EPC solenoid valve of of the fan pump
2 the fan pump Radiator side: 1.69/1.32 ± 0.39 mA
Standard/+55°C speci- {17.2/13.5 ± 4.0 kg/cm2}
fications All levers in neutral
O/C side: 1.81/1.32 ± 0.25 mA
{18.5/13.5 ± 4.0 kg/cm2}
Internal defect of fan If failure causes 1 and 2 are normal, the fan pump or fan motor may have
3
pump or fan motor failed. Check them directly.
PC2000-8 41
SEN02104-00

© 2006 KOMATSU
All Rights Reserved
42
SEN02105-00
PC2000-8
PC2000-8 20001 and up
Troubleshooting of mechanical system
(S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 3
Method of using troubleshooting charts ............................................................................................... 3
S-1 Starting performance is poor ......................................................................................................... 6
S-2 Engine does not start..................................................................................................................... 7
S-3 Engine does not pick up smoothly............................................................................................... 10
S-4 Engine stops during operations ....................................................................................................11
S-5 Engine does not rotate smoothly ................................................................................................. 12
S-6 Engine lacks output (or lacks power)........................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 16
S-9 Oil becomes contaminated quickly .............................................................................................. 17
S-10 Fuel consumption is excessive.................................................................................................. 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 19
S-12 Oil pressure drops ..................................................................................................................... 20
1
S-13 Oil level rises (Entry of coolant or fuel) ...................................................................................... 21

S-14 Coolant temperature becomes too high (overheating) .............................................................. 22
S-15 Abnormal noise is made ............................................................................................................ 23
S-16 Vibration is excessive ................................................................................................................ 24
2
Troubleshooting of mechanical system (S-mode) 1

Method of using troubleshooting charts 1
The troubleshooting chart consists of the “ques-
tions”, “check items”, “causes”, and “troubleshoot-
ing” blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Simple check items used by the serviceman to
narrow down the causes.
They corresponds to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E:Causes to be referred to for questions and check items
Q:Causes related to questions and check items
w:Causes highly probable among ones marked with Q
a When narrowing the “causes”, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
3
<Example of troubleshooting> Exhaust smoke is black

Let us assume that [Clogged air cleaner element] is taken to be the cause of black exhaust gas. Three symp-
toms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was
lost gradually], and [Air cleaner clogging caution lamp is flashing].
4
If we look for the linkage of these three phenomena to possible causes, we find that they have causal rela-
tionship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
5
S-1 Starting performance is poor 1

General causes for poor starting performance are Causes
q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Insufficient supply of fuel
Defective alternator (generator section)

q
Defective alternator (regulator section)

Stuck or seized supply pump plunger
q Insufficient intake of air
Defective intake air heater system

Improper selection of fuel (particularly during winter)
Defective or deteriorated battery

q
Clogged feed pump gauze filter

Coolant in exhaust pipe
Worn piston ring and cylinder

q
Clogged air cleaner element
Clogged fuel filter element

a The common rail fuel injection system (CRI) recognizes
the fuel injection timing electrically. Accordingly, even if
the starting operation is carried out, the engine may not
Defective injector
start until the crankshaft revolves 2 turns at maximum.
This phenomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of
machine operation
Operated for long period E E E E
Starting perfor- Became worse gradually Q w w Q Q

mance Engine starts easily when warm w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters not carried out according to Operation and Maintenance
Manual
w w w Q Q
Engine oil replenished more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge (if monitor is
installed)
w w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
When priming pump is operated, it makes no reaction or it is heavy E w Q Q
Starting motor cranks engine slowly w
Fuel does not flow out if air bleeding plug of fuel filter is
While engine is removed w w
cranked with start-
ing motor, If spill hose from injector is disconnected,
Q w
Check items
little fuel spills

When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
w
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
There is hunting from engine (rotation is irregular) Q Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter and strainer directly q
q
Troubleshooting
Inspect feed pump gauze filter directly

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change on some cylinders q
When starting switch is turned to HEAT, intake air heater mount does not become
warm
q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q

engine at low idle? None q
When specific gravity of electrolyte and voltage of battery are measured, they are
low
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
6
S-2 Engine does not start 1

a) Engine does not turn Causes
General causes why engine does not turn
Defective starting motor (safety relay section)

q Engine seized inside
Defective connection of battery terminal
Defective starting motor (motor section)

o See “S-4 Engine stops during operations”.
q Water hammer caused by coolant which entered cylinder
Defective PTO or hydraulic pump

Defective electrical system

q
Defective steering circuit wiring

q Problem in drive devices on applicable machine side
o Troubleshoot the applicable machine side
Broken flywheel ring gear
Defective starting switch

Defective battery relay
Questions
Degree of machine opera- Operated for long period

tion E E
Condition of horn when Horn does not sound Q Q
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages w
Makes rattling noise and does not turn Q Q
Inspect flywheel ring gear directly q
Carry out troubleshooting

When specific gravity of electrolyte and voltage of battery are measured, they are low q
Troubleshooting
There is not voltage (20 – 30 V) between battery relay terminal B

and terminal E q
Turn starting switch OFF, When terminal B and terminal C of starting switch are connected, q
connect cord, turn the engine starts
switch ON and carry out When terminal B and terminal C at safety relay outlet are con-
in H-mode
in E-mode
troubleshooting nected, engine starts q
When terminal B and terminal C at safety relay outlet are con-
nected, engine does not start q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
7
b) Engine turns but no exhaust smoke comes out Causes

General causes why engine turns but no exhaust smoke
Defective operation of overflow valve (Does not close)

comes out
q Fuel is not being supplied
Leaking, clogging and entry of air to fuel piping

q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Wrong connection of supply pump PCV

Seized, abnormally worn feed pump
Defective operation of flow damper

Broken supply pump shaft spline
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Use of improper fuel
Defective injector
Degree of
Operated for long period E E E
Questions
machine operation
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E E
Non-specified fuel is being used w
w w E E Q
Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is no fuel in it w Q w
w
Check items
Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy w Q Q
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q Q Q w Q
cranked with out
starting motor, If spill hose from injector is disconnected, little fuel spills Q w w w w Q

Inspect fuel filter directly q
Inspect feed pump gauze filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to “No-pressure feed by supply pump error
q q q
(*1)” in E-mode
Carry out troubleshooting according to “Abnormality in PCV1 (*2) or Abnormality
q
in PCV2 (*3)” in E-mode
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] in E-mode
8
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Defective coolant temperature sensor and/or wiring harness

General causes why exhaust smoke comes out but engine
Worn dynamic valve system (Valve, rocker lever, etc.)

does not start
q Lack of rotating force due to defective electrical system
Leaking, clogging of fuel system, and entry of air

q Insufficient supply of fuel
Stuck and/or seized supply pump plunger

Clogged injector and/or defective spray
q Improper selection of fuel
Worn piston ring and/or cylinder liner
Defective intake air heater system

Clogged fuel filter and/or strainer

Use of improper fuel

Degree of machine Operated for long period
operation
E E E E
Suddenly failed to start w w Q
Questions

Manual
w w w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed)
w
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w w
When fuel filter is removed, there is no fuel in it w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
While engine is Fuel does not flow out if air bleeding plug of fuel filter is
Q Q w w
cranked with starting removed
motor, If spill hose from injector is disconnected, little fuel spills Q Q w
w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
q
Troubleshooting
Inspect fuel filter, strainer directly

Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)”
in E-mode
q
When injector unit is tested, spray condition is bad q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Coolant temperature gauge does not indicate normally (if coolant temperature
gauge is installed)
q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
9
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Defective operation of flow damper (Maximum leakage from injector)

q Defective spray condition of fuel
q Controller is controlling in derate mode
(limiting injection rate (output) because of an error in electri-
Seized turbocharger or interference of turbocharger

cal system)
Leaking, clogging of or entry of air to fuel piping

Clogged injector and/or defective spray


Improper valve clearance

Degree of
machine operation
Operated for long period E E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters not carried out according to Operation and Maintenance Manual w w w
Q w
Color of exhaust Blue under light load w

Check items
gas is Black w Q w w
When engine is cranked, interference sound is emitted from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q

Inspect valve clearance directly q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy q

Inspect feed pump gauze filter directly
Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)” in
E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change on some cylinders
q q
Adjusting
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
10
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
q Seized parts inside engine
Broken dynamic valve system (valve, rocker arm, etc.)
Broken auxiliary equipment (pump, compressor, etc.)

q There is overheating
Broken or seized piston and/or connecting rod

q Problem in drive devices on applicable machine side
o Troubleshoot the applicable machine side

Broken or seized crankshaft bearing
Leaking and/or clogged fuel piping
Defective PTO or hydraulic pump

Broken supply pump shaft spline

Broken or seized feed pump
Broken or seized gear train
Degree of machine
operation
Operated for long period EE
Abnormal noise was heard and engine stopped sud-
denly w w w w Q w Q w w
Questions
Condition when engine Engine overheated and stopped w Q Q

stopped
Engine stopped slowly w Q Q
Engine stopped after hunting w Q Q Q Q
Manual w w
Fuel level monitor indicates low level (if monitor is installed) w
Metal particles are found when oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is Turns in opposite direction w
cranked by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Inspect piston and connecting rod directly q
Inspect crankshaft bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect feed pump directly q
in H-mode
Carry out troubleshooting according to “No-pressure feed by supply pump

error (*1)” in E-mode
q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is
removed
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
11
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
q Air in fuel system
Defective operation of flow damper (Maximum leakage from injector)

q Defective speed sensor (Error at degree that it is not indicated)
Clogged injector and/or defective spray (dirt in injector)
Defective G (Bkup) speed sensor or wiring harness

Defective Ne speed sensor and/or wiring harness
Leaking or clogging or entry of air to fuel piping

Low setting of low idle speed
Clogged fuel filter or strainer

Degree of machine
operation
Operated for long period E E
Questions
Occurs at a certain speed range Q Q Q

Occurs at low idle w Q Q Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w Q Q
Replacement of filters not carried out according to Operation and Maintenance Manual w w
Check items
Rust and water are found when fuel tank is drained Q Q


Troubleshooting

change on some cylinders q q
Carry out troubleshooting according to “Abnormality in engine Ne speed sensor (*1)” in E-
mode
q
Carry out troubleshooting according to “Abnormality in engine Bkup speed sensor (*2)” in E-
mode
q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Remedy
Add
*1: Failure code [CA689] and [CB689]

*2: Failure code [CA778] and [CB778]
1
12
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Causes
Defective installation of boost pressure sensor (air leakage)

Insufficient supply of fuel
Defective fuel temperature sensor and/or wiring harness

q
Defective boost pressure sensor and/or wiring harness

Clogged injector or defective spray (dirt in injector)

Defective drive of injector (signal and/or solenoid)
q Overheat
oSee “S-14 Coolant temperature becomes too

high (Overheating)”

Air leakage from air intake piping

Leaking or clogged fuel piping
(limiting injection rate (output) because of an

error in electrical system)

Degree of machine
operation Operated for long period E E E E E
Q Q Q Q
Questions
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters not carried out according to Operation and Mainte-
nance Manual
w Q
Engine oil replenished more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Color of exhaust Black w w
gas Blue under light load w
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low w
w
Check items
When engine is cranked, interference sound is emitted from around turbocharger

High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when
load is applied
w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w Q
There is hunting from engine (rotation is irregular) Q Q Q Q
Blow-by gas is excessive w w

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting

Carry out troubleshooting according to “No-pressure feed by supply
pump error (*1)” in E-mode
q
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change on some cylinders q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to “Abnormality in charge pressure
sensor (*2)” in E-mode
q
Carry out troubleshooting according to “Abnormality in fuel temperature
sensor (*3)” in E-mode q
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Clean
Clean
Clean
13
*2: Failure code [CA122] and failure code[CA123] in E-mode
14
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head
Defective coolant temperature sensor or wiring harness

q Excessive injection of fuel

Clogged fuel spill piping (on cylinder head side)

q Overheat

o See “S-14 Coolant temperature becomes too high

(Overheating)”
Improper fuel injection pressure

(limiting injection rate (output) because of an error in
Crushed or clogged muffler
Clogged or seized injector

electrical system)
Abnormally worn injector
Improper injection timing

Degree of
machine operation Operated for long period E E E E
Suddenly became black w Q Q Q
Questions
Color of exhaust
gas
Gradually became black w Q Q
Blue under light load w
Non-specified fuel is being used Q Q
Oil replenished more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, and clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Q w
Check items

Torque converter stall speed or pump relief speed is high
(Fuel is injected excessively)
Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

When turbocharger is rotated by hand, it is fount to be heavy q
q
Troubleshooting
Inspect valve clearance directly

When muffler is removed, exhaust sound improves q
Carry out troubleshooting according to “No-pressure feed by supply pump error
(*1)” in E-mode
q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change on some cylinder q
Inspect fuel spill piping (on cylinder head side) directly q q
Carry out troubleshooting according to “Abnormality in coolant temperature sen-
sor error (*2)” in E-mode
Adjusting
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
15
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal combustion of oil
Turbocharger 1
q Long-time operation of engine at low idle or high idle
Oil leakage from oil pan, cylinder head, etc.

Worn or damaged valve (stem, guide, seal)
(Do not run engine continuously at idle without load for
more than 20 minutes)

Clogged breather or breather hose
Dust sucked in from intake system
q External leakage of oil
Wear of parts in lubrication system
Worn seal at turbocharger end
Worn or damaged rear oil seal

q
Oil leakage from oil drain plug

Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of machine oper- Operated for long period
E E E E
Questions
ation
Oil consumption suddenly increased w Q
Oil replenished more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is contaminated with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is contaminated with oil w
Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w
Check items
There is oil in coolant w

Oil level in PTO is increasing w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found contaminated abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
16
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
Clogged breather and/or breather hose

q Use of improper fuel

q Use of improper oil
Operation under excessive load
Worn valve and/or valve guide

q
Defective oil filter safety valve
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Degree of machine operation Operated for long period E E E
Questions
Non-specified fuel is being used Q

Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is
installed) w Q
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is contaminated with oil w
Engine oil temperature rises quickly w
Blue under light load w
Check items
Color of exhaust gas

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

q q
Troubleshooting
When compression pressure is measured, it is found to be low

Inspect breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy Clean
—
17
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
q Leakage of fuel
Defective coolant temperature sensor or wiring harness

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

Degree of
E E E
Questions
machine operation Operated for long period

More than other machines of same model Q Q Q
Condition of fuel
consumption
Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is
low w
Check items
Low idle speed is high Q

Torque converter stall speed or hydraulic pump relief speed is high Q
Color of exhaust Black Q Q Q
gas White Q
Remove and inspect head cover directly q

Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to “No-pressure feed by supply pump error (*1)” in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
q
If spill hose from injector is disconnected and measured, much fuel spills q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” q
Confirm or with monitoring function on machine monitor q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is mixed in coolant Causes
q Internal leakage in lubrication system
Damaged cylinder liner O-ring and/or hole caused by pitting

q Internal leakage in cooling system
Broken cylinder head and/or head gasket
Insufficient protrusion of cylinder liner

Broken oil cooler core and/or O-ring
Cracks inside cylinder block
Degree of machine
Operated for long period E E
Questions
operation
Suddenly increased Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
Check
items
There are excessive air bubbles in radiator, coolant spurts back w w
Pressure-tightness test of cylinder head shows there is leakage q

Troubleshooting
Inspect cylinder block and liner directly q q
Inspect cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy
19
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage, clogging, and/or wear of lubrication system
Defective oil pressure sensor and/or defective wiring harness

q Defective oil pressure control
q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Defective oil level sensor and/or wiring harness

Leaking, crushed, clogged hydraulic piping
Clogged and/or broken pipe in oil pan
Defective oil pump relief valve

Coolant and fuel mixing in oil
Clogged strainer in oil pan
Worn journal of bearing
Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Degree of
E E E
Questions
Operated for long period

machine operation
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters not carried according to Operation and Maintenance Manual w
Indicates pressure drop at low idling time w Q
Oil pressure Indicates pressure drop at low and high idling times Q w w w Q
monitor
(if installed) Indicates pressure drop on slopes w
Indicates pressure drop occasionally w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking or crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

q q
Troubleshooting
Inspect oil pan strainer and pipe directly

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve and spring of oil pump relief valve are fatigued and damaged q
Inspect oil filter directly q
Carry out troubleshooting according to “Abnormality in oil pressure sensor (*1)” in E-mode q
If oil level sensor is replaced, oil level monitor indicates normally q
Adjusting
Replace
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
Clean
—
Add
20
S-13 Oil level rises (Entry of coolant or fuel) 1
General causes why oil level rises Causes

q Coolant in oil (milky)
Clogged water pump drain hole (breather hole) and/or defective seal
q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in cool-

ant”.
Defective seal of auxiliary equipment (pump, compressor)

Broken oil cooler core and/or O-ring

Fuel leakage inside head cover
Worn or damaged rear oil seal

Cracks inside cylinder block
Defective thermostat seat

Defects in supply pump
Questions
Degree of
Fuel consumption increasing w w
Coolant replenished more frequently Q w
There is oil mixed in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles
appears, or coolant spurts back w Q
Check items
Exhaust smoke is white Q Q

Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant comes out w
Oil level in PTO is low w

Remove and inspect head cover directly q
q q
Troubleshooting
Inspect cylinder block and/or liner directly

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
21
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Causes
q Lack of cooling air (deformation, and/or damages of fan)

q Drop in heat dissipation efficiency
q Problem in coolant circulation system
q Problem in RAD fan pump or motor
Defective radiator cap (pressure valve)
Defective coolant temperature gauge
Defective radiator fan pump or motor

Defective operation of thermostat
Clogged or crushed radiator fins
Worn or deformed fan pulley

Clogged or broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of
Questions
Sudden overheated Q w Q
Condition for
Persistent overheating Q w w Q
Coolant tempera- Rises quickly Q w
ture gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Fan is deformed or worn w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator and coolant spurts back w
Check items
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard on applicable machine side are clogged with
dirt or mud
w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w

Inspect cylinder liner directly q
q
Inspect oil cooler directly

Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

When operation of thermostat is tested, it does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
in H-mode
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt and pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
22
S-15 Abnormal noise is made 1

General causes why abnormal noise is emitted Causes
q Abnormality due to defective parts
Defective inside of muffler (dividing board out of position)

Broken dynamic valve system (valve and/or rocker lever)
Leakage of air between turbocharger and cylinder head
q Abnormal combustion
q Air leakage from air intake system
Excessive wear of piston ring and/or cylinder liner

a Judge if the noise is an internal noise or an external noise
before starting troubleshooting.
a While the engine is not sufficiently warmed up, it is operated in
Interference or seizure of turbocharger
Removed or seized gear train bushing

the low-temperature mode. Accordingly, the engine sound
rises slightly higher. This is no abnormality, however.
a When the engine is accelerated, the engine sound rises
Deformed or worn cooling fan

Improper gear train backlash
slightly for approx. 3 seconds maximum. This is no abnormal-
Clogged or seized injector

ity, however.
Dirt caught in injector

Degree of machine
operation Operated for long period E
Questions
Condition of abnor- Gradually increased Q Q

mal noise Suddenly increased Q Q Q
Non-specified fuel is being used Q
Oil replenished more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around EGR gas piping
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is emitted around muffler w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low w Q
Color of exhaust Blue under light load w

gas Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is fount to be heavy q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan directly q
q q
Abnormal noise is heard only when engine is started q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
23
S-16 Vibration is excessive 1

General causes why vibration occurs Causes
q Defective parts (abnormal wear, breakage, etc.)
Broken output shaft and/or parts in damper on installed machine side

Misalignment between engine and devices on installed machine side
q Misalignment between installed machine
q Abnormal combustion
a If abnormal noise vibration occur, carry out troubleshooting for “S-15
Abnormal noise is emitted”, too.
Stuck dynamic valve system (valve, rocker lever, etc.)
Loose engine mounting bolts and/or broken cushions

Worn main bearing and/or connecting rod bearing
Worn front support spigot joint portion

Improper gear train backlash
Worn camshaft bushing
Degree of machine
E E E E
Questions
operation Operated for long period
Condition of vibra- Suddenly increased Q Q

tion Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust smoke is black w

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect front support spigot joint portion directly q
Inspect output shaft or inside of damper directly q
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
24
SEN02105-00

© 2006 KOMATSU
All Rights Reserved
26
SEN02133-00
PC2000-8

PC2000-8 20001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
General information on disassembly and assembly ....................................................................................... 2
How to read this manual ...................................................................................................................... 2
Coating materials list............................................................................................................................ 4
Special tool list ..................................................................................................................................... 7
Sketches of special tools.................................................................................................................... 10
PC2000-8 1
SEN02133-00 50 Disassembly and assembly
General information on disassembly and assembly 1

How to read this manual 1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are deemed neces- q The [Removal] section contains procedures
sary for removal or installation of parts are and precautions for implementing the work,
described as A1,•••X1 etc. and their part know how and the amount of oil or coolant to
names, part numbers and quantities are be drained.
described in the special tool list. q Various symbols used in the Removal Section
q Also the following information is described are explained and listed below.
in the special tool list. k : This mark indicates safety-related pre-
1) Necessity cautions that must be followed when
t : Special tools that cannot be substi- implementing the work.
tuted and should always be used a : Know-how or precautions for work
(installed). [*1] : This mark shows that there are instructions
q : Special tools that will be useful if avail- or precautions for installing parts.
able and are substitutable with com- 6 : This mark shows the amount of oil or coolant
mercially available tools. to be drained.
2) Distinction of new and existing special 4 : Weight of part or component
tools
N: Tools newly developed for this
model. They respectively have a Installation
new part number.
q Except where otherwise instructed, installation
R: Tools with upgraded part numbers.
of parts is done in the r evers e order of
They are remodeled from already
removal.
available tools for other models.
q Instructions and precautions for installing parts
Blank: Tools already available for other
are shown with [*1] mark in the Installation
models. They can be used without
Section, identifying which step the instructions
any modification.
are intended for.
3) Circle mark Q in sketch column: q Marks shown in the Installation Section stand
q The sketch of the special tool is pre- for the following.
k : Precautions related to safety in execu-
sented in the section of “Sketches of
special tools”. tion of work.
q Part No. of special tools starting with a : This mark gives guidance or precautions
* *** ****
79 T- - : when doing the procedure.
2 : Type of coating material
means that they can not be supplied
3 : Tightening torque
from Komatsu in Japan (i.e. locally
made parts).
5 : Quantity of oil or coolant to be added
a General tools that are necessary for
Sketches of special tools
removal or installation are described as
[1],[2]•••etc. and their part names, part q Various special tools are illustrated for the con-
numbers and quantities are not described. venience of local manufacture.
2 PC2000-8
2. Disassembly and assembly of assemblies Disassembly

q In Disassembly section, the work procedures,
Special tools precautions and know-how for carrying out
q Special tools which are deemed neces- those procedures, and quantity of the oil and
sary for removal or installation of parts are coolant drained are described.
described as A1,•••X1 etc. and their part q The meanings of the symbols used in Disas-
names, part numbers and quantities are sembly section are as follows.
described in the special tool list. k : This mark indicates safety-related pre-
q Also the following information is described cautions that must be followed when
in the special tool list. implementing the work.
1) Necessity a : Know-how or precautions for work
t : Special tools that cannot be substi- 6 : Quantity of oil or coolant drained
tuted and should always be used
(installed).
q : Special tools that will be useful if avail-
able and are substitutable with com- Assembly
mercially available tools. q In Assembly section, the work procedures, pre-
2) Distinction of new and existing special cautions and know-how for carrying out those
tools procedures, and quantity of the oil and coolant
N : Tools newly developed for this added are described.
model. They respectively have a q The meanings of the symbols used in Assem-
new part number. bly section are as follows.
R : Tools with upgraded part numbers. k : Precautions related to safety in execu-
They are remodeled from already tion of work.
available tools for other models. a : This mark gives guidance or precautions
Blank : Tools already available for other when doing the procedure.
models. They can be used without 2 : Type of coating material
4
any modification.
: Tightening torque
3) Circle mark Q in sketch column:
5 : Quantity of oil or coolant to be added
q The sketch of the special tool is pre-
sented in the section of “Sketches of
Sketches of special tools
special tools”.
q Part No. of special tools starting with q Various special tools are illustrated for the con-
venience of local manufacture.
* *** ****
79 T- - :
means that they can not be supplied
from Komatsu in Japan (i.e. locally
made parts).
a General tools that are necessary for

removal or installation are described
as [1],[2]•••etc. and their part names,
part numbers and quantities are not
described.
PC2000-8 3
Coating materials list 1

a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat and cold-resis-
ThreeBond tant, vibration-resistant, impact-resistant seal-
419-15-18131 100 g Tube
1207B ant.
• Used to seal transfer case, etc.
4 PC2000-8
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used to lubricate sliding portions.
disulfide lubricant
LM-G 09940-00051 60 g Can

Molybdenum
(to prevent squeaking)

• Used to prevent scuffing and seizure of press-
fitted portions, shrink-fitted portions, and
LM-P 09940-00040 200 g Tube
threaded portions.
• Used to lubricate linkages, bearings, etc.
SYG2-400LI
G2-LI SYG2-350LI
G0-LI (*) SYG2-400LI-A
SYG2-160LI Various Various • General purpose type.
*: For cold SYGA-160CNLI
district SYG0-400LI-A (*)
SYG0-16CNLI (*)
SYG2-400CA
SYG2-350CA • Used for bearings used at normal temperature
G2-CA SYG2-400CA-A Various Various
SYG2-160CA under light load in contact with water or steam.
SYGA-160CNCA
• Used for parts under heavy load.
Caution:
Grease
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to ball bearings like swing
disulfide grease SYG2-400M-A 400 g x 20 container circle bearings, etc.
LM-G (G2-M) SYGA-16CNM 16 kg Can
• The grease should be applied to work equip-
ment pins at their assembly only, not applied for
greasing afterwards.
Hyper White • Seizure resistance and heat resistance higher
Grease G2-T, SYG2-400T-A 400 g Bellows-type
SYG2-16CNT than molybdenum disulfide grease.
G0-T (*) container
*: For cold SYG0-400T-A (*) 16 kg Can • Not conspicuous on machine since color is
district SYG0-16CNT (*) white.
Biogrease
G2-B, G2-BT (*) SYG2-400B
*: For use at SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural
high tempera- SYG2-400BT (*) container bacteria in short period, it has less effects on
ture and under SYGA-16CNBT 16 kg Can microorganisms, animals, and plants.
high load (*)
SUNSTAR • Used as primer for cab side.

Glass con-
PAINT PRIMER 20 ml tainer (Using limit: 4 months after date of manu-
580 SUPER facture)
417-926-3910
SUNSTAR • Used as primer for glass side.
GLASS Glass con-
PRIMER 580 20 ml tainer (Using limit: 4 months after date of manu-
SUPER facture)
Adhesive for cab glass
• Used as primer for painted surface on cab

SUNSTAR Glass con- side.
PAINT PRIMER 22M-54-27230 20 ml
Primer
tainer (Using limit: 4 months after date of manu-

435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR surface on glass side and for hard polycar-
GLASS
PRIMER 22M-54-27240 150 ml Can bonate-coated surface.
435-41 (Using limit: 4 months after date of manu-
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass con-
SASH PRIMER 22M-54-27250 20 ml tainer (Using limit: 4 months after date of manu-
GP-402 facture)
PC2000-8 5
Cate-
gory Komatsu code Part number Q'ty Container Main features and applications
SUNSTAR • “S” is used for high-temperature season

PENGUINE Polyethyl- and “W” for low-temperature season as
SEAL 580 417-926-3910 320 ml ene con- adhesive for glass.
SUPER “S” or tainer (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
Polyethyl- • Used as adhesive for glass.

Sika Japan,
Sikaflex 256HV 20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of manu-
tainer
Adhesive for cab glass

facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR Polyethyl- • Used to seal joints of glass parts.
PENGUINE 417-926-3920 320 ml ene con- (Using limit: 4 months after date of manu-
SEAL No. 2505 tainer facture)
Caulking material
SEKISUI Polyethyl- • Used to seal front window.

SILICONE 20Y-54-55130 333 ml ene con- (Using limit: 6 months after date of manu-
SEALANT tainer facture)
• Used to seal joint of glasses.
GE TOSHIBA Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
TOSSEAL 381 (Using limit: 12 months after date of manu-
facture)
6 PC2000-8
Special tool list 1
a Tool part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a Necessity: t ........... Cannot be substituted, must always be installed (used)
q ........... Extremely useful if available or can be substituted with commercially available
part
a New/Remodel: N ........... Tools with new part numbers, newly developed for this model
R:........... Tools with upgraded part numbers, remodeled from items already available for
other models
Blank: ... Tools already available for other models, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools)
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part name Nature of work, remarks
Removal, installation Tightening of cylinder head

of cylinder head 1 790-331-1110 Wrench q 1 bolt
assembly
3 795-931-1100 Seal puller t 1 Extraction of oil seal
795T-621-1430 Plate t 1 N Q
Removal, installation 795T-621-1440 Push tool t 1 N Q
of engine front seal 4 01050-32240 • Bolt t 3 Press fitting of oil seal
A
01050-32225 • Bolt t 3
01640-02232 • Washer t 3
3 795-931-1100 Seal puller assembly t 1 Extraction of oil seal
Removal, installation 795T-621-1540 Push tool t 1 N Q
of engine rear seal 5 01050-32060 • Bolt t 5 Press fitting of oil seal
01640-02032 • Washer t 5
790-101-5621 Plate t 1
Swing machinery 1 790-101-5641 Grip t 1 Press fitting of oil seal
F
assembly 01010-51240 Bolt t 1
2 796T-626-1120 Push tool t 1 Q Press fitting of bearing
Final drive assembly J 791-585-1510 Installer t 1 Installation of floating seal
Assembly of carrier 1 791-575-1520 Installer t 1 Installation of floating seal
roller assembly 2 796T-930-1110 Push tool t 1 N Q Press fitting of ring
Assembly of idler 3 791-542-1520 Installer t 1 Installation of floating seal
L 790-401-1700 Lifting tool t 1 Removal, installation of track
Track roller assembly 4
790-434-1021 Adapter t 1 roller
Assembly of track 5 796-675-1510 Installer t 1 Installation of floating seal

roller assembly 6 791-601-1000 Oil pump t 1 Filling oil
1 790-434-1502 Remover & installer t 1
Track shoe assembly R 2 790-101-4300 Cylinder t 1 Removal, installation of

(1,471 kN {150 ton}) master pin
3 790-101-1102 Hydraulic pump t 1
Installation of hydrau-
lic pump input shaft S 796T-867-1810 Push tool t 1 N Q Press fitting of oil seal
oil seal
Hydraulic pump Removal, installation of
S1 796-770-1301 Oil stopper q 2
assembly hydraulic pump
PC2000-8 7
New/remodel
Necessity
Symbol
Sketch
Q'ty
790-101-2501 Push puller t 1

790-101-2510 • Block 1
790-101-2520 • Screw 1
Disassembly, assem- 791-112-1180 • Nut 1

Disassembly, assembly of
bly of center swivel T 790-101-2540 • Washer 1
center swivel joint assembly
joint assembly 790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2660 • Adapter 2
790-502-1003 Cylinder repair stand t 1 Disassembly, assembly of
1
790-101-1102 Pump t 1 hydraulic cylinder
790-102-4300 Wrench assembly t 1 Removal, installation of pis-
2
790-102-4310 Pin t 2 ton assembly
3 790-720-1000 Expander t 1 Installation of piston ring
796-720-1690 Ring (for bucket) t 1
07281-02169 Clamp t 1
796-720-1710 Ring (for arm) t 1
4 Compression of piston ring
07281-02709 Clamp t 1
796-720-1730 Ring (for boom) t
07281-03209 Clamp t
790-201-1702 Push tool kit 1
790-201-1881 • Push tool 1
Press fitting of roll bushing

Bucket cylinder
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Hydraulic cylinder 791-863-1110 Push tool t 1
U 5
assembly 790-101-5421 Grip t 1 Arm cylinder
01010-51240 Bolt t 1
792-630-1300 Push tool t 1
790-101-5421 Grip t 1 Boom cylinder
01010-51240 Bolt t 1
790-201-1500 Push tool kit t 1
790-201-1640 • Push tool 1
Bucket cylinder
Press fitting of dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
792-715-1400 Plate t 1
6
790-101-5421 Grip t 1 Arm cylinder
01010-51240 Bolt t 1
790-445-4220 Plate t 1
790-101-5421 Grip t 1 Boom
01010-51240 Bolt t 1
8 PC2000-8
New/remodel
Necessity
Symbol
Sketch
Q'ty
796T-870-1150 Sleeve t 1 Q
796T-870-1170 Sleeve t 1 Q
796-870-1180 Adapter t 1
796T-870-1190 Plate t 1 Q
Arm assembly V 796-900-1230 Screw t 1 Extraction of boom top pin

01582-33024 Nut t 1
01643-33080 Washer t 1
Puller
790-101-4000 t 1
(1,471 kN {150 ton})
790-101-1102 Pump t 1
Operator’s cab glass 1 793-498-1210 Lifter (Suction cup) t 4 Installation of window glass
(stuck glass) 2 20Y-54-13180 Adapter t 2 Fixture of window glass
799-703-1200 Service tool kit t 1

Vacuum pump
799-703-1100 (for 100 V) t 1
X
Air conditioner Vacuum pump Filling with refrigerant
3 799-703-1111 t 1
assembly (for 220 V) (air conditioner gas)
Vacuum pump
799-703-1121 (for 240 V) t 1
799-703-1401 Gas leak detector t 1
PC2000-8 9
Sketches of special tools 1
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
A4 Plate
A4 Push tool
10 PC2000-8
sketches.
A5 Push tool
F2 Push tool
PC2000-8 11
sketches.
L2 Push tool
S Push tool
12 PC2000-8
sketches.
V Sleeve
V Sleeve
PC2000-8 13
sketches.
V Plate
14 PC2000-8
SEN02133-00
© 2006 KOMATSU
All Rights Reserved
16
SEN02134-00
PC2000-8

PC2000-8 20001 and up
50 Disassembly and assembly 1
Engine and cooling system (12V140E-3)

Engine and cooling system (12V140E-3)........................................................................................................ 2
Removal and installation of power container assembly ....................................................................... 2
Removal and installation of engine, PTO and hydraulic pump assembly ............................................ 7
Removal and installation of radiator assembly................................................................................... 18
Removal and installation of aftercooler assembly .............................................................................. 19
Removal and installation of hydraulic oil cooler assembly ................................................................. 21
Removal and installation of fuel cooler assembly .............................................................................. 22
Removal and installation of cooling assembly ................................................................................... 23
Removal and installation of fan motor assembly................................................................................ 27
Removal and installation of fuel tank assembly ................................................................................. 28
PC2000-8 1
Engine and cooling system (12V140E-3) 1
Removal and installation of power

container assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
Vacuum pump
799-703-1100 t 1
(100 V)
Vacuum pump
X 3 799-703-1111 t 1
(220 V)
4. Drain hydraulic oil.
6
Vacuum pump
799-703-1121 t 1 Hydraulic tank: 1,300 l
(240 V)
799-703-1401 Gas leak detector t 1 5. Disconnect hoses (2) to (6).
a Prepare a container and oil plug to catch
Removal oil leaks.
the ground and stop the engine.
k Loosen the oil filler cap gradually to release
the internal pressure of the hydraulic tank
k Set the work equipment lock lever to the
lock position.
k Disconnect the cable from the negative (–)
terminal of the battery.
k Collect the refrigerant (air conditioner gas:
R134a).
k Always wear protective glasses when col-
lecting or filling the refrigerant (air condi-
tioner gas: R134a). Refrigerant in your eyes
could cause blindness. Only the qualified
personnel shall perform collection and fill-
6. Disconnect suction hoses (7) to (9).
ing of the refrigerant.
a MIKALOR clamp. [*1]
1. Remove counterweight assembly, referring to a Apply a marking to the hose end and tube
"Removal and installation of counterweight so that their original insertion positions
assembly". may be identified in later reference. (See
the following figure.)
2. Close fuel tank valve.
3. Remove clamp and drain coolant from the

hose (1).
6 Coolant: 180 l
2 PC2000-8
10. Lift and remove tail pipes (14).
7. Disconnect fuel hose (10).

11. Remove cover A (15).
8. Disconnect heater hoses (11). [*2]
a Disconnect 4 air conditioner hoses AH 12. Remove bracket (16).
inside the container. (Refer to next item)
13. Disconnect 4 oil hoses (17) and 2 oil hoses
(18).
14. Remove cover (19).
9. Disconnect clips (12) and 4 air conditioner

hoses (13) inside the power container. [*3]
a The air conditioner hoses (13) are com-
posed of 2 stages.
a Be careful for the air conditioner circuit 15. Disconnect connectors (20).
hoses so that dirt, water may not enter.
a The heater hoses HS and fuel hoses FH 16. Disconnect clamp (21).
have been disconnected in the previous a HSTT: Hydraulic tank
step.
PC2000-8 3
17. Open battery cover (22) from the bottom of the a Harnesses (27) and (28) have been pulled
ladder R located behind the operator cab. out.
18. Disconnect 2 negative terminals (23) and 2 21. Disconnect fuel hose (29) from the bottom rear
positive terminals (24). of the power container.
19. Disconnect connectors (25) and (26) from the 22. Disconnect hose clamps (30).
rear of the battery.
20. Pull out harnesses (27) and (28).
4 PC2000-8
23. Lift and remove deck assembly (31).

4 Deck assembly: Approx. 260 kg
26. Lift and remove power container assembly

(35).
24. Lift and remove deck assembly (32). 4 Power container assembly:
4 Deck assembly: Approx. 260 kg Approx. 16,300 kg
25. Remove power container M30 mounting bolts

(33); 5 bolts each from 4 places. [*4]
a The plate (34) can be removed from back-
side.
PC2000-8 5
Installation a Check that there is no defect or deterioration

q Carry out the installation in the reverse order of on the O-ring.
removal. a When connecting the piping for refrigerant,
[*1] Suction hose clamp apply the compressor oil for the new refriger-
a Use new MIKALOR clamp. ant to the O-ring (Denso: ND-OIL8 or ZEXEL:
2 Entire perimeter of hose on the tube side: ZXL100PG (PAG46 or equivalent)).
Adhesive (ThreeBond No.4314)
a Apply the adhesive uniformly along the entire 3 Hose clamp: 8.83 – 14.7 Nm {0.9 – 1.5 kgm}
perimeter 3 Hose thread M16 × 1.5:
1) Align the hose to the original position (marked 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
position). (Air hose insertion depth: Min. 80 3 Hose thread M24 × 1.5:
mm) 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
2) Place the bridge (BR) under the clamping bolt
and adjust the overlapping (b) between the
bridge (BR) and band to 5 mm minimum.
(b) dimension: Min. 5 mm
2 Threaded portion (BC) of clamping bolt:
Lubricant (PANDO 18B from ThreeBond)
a Never use an impact wrench.
a Displace the tightening positions of the adja-
cent clamps by 180°.
q When the current hose is reused

3)Align the clamp position to the trace of the
clamp left on the hose.
3 Clamping bolt: Min. 6 Nm {0.6 kgm}
[*4]
3
q When a new hose is used Power container mounting bolt:
4) Tighten the bolt until BDG dimension meets 3,430 – 4,212 Nm {350 – 430 kgm}
the following.
Hoses (7) and (9): 12 – 15 mm q Refilling with oil (Hydraulic tank)
Hose (8): 17 – 20 mm Fill oil up to the specified level from the oil filler
port, start the engine to circulate oil in the pipe
and then confirm the oil level again.
5 Hydraulic tank (Hydraulic tank refill oil
capacity): Approx. 1,300 l
q Refilling with coolant
Fill coolant up to the specified level from the
coolant filler, start the engine to circulate the
coolant and then confirm the coolant level
again.
5 Coolant: 180 l
q Filling of refrigerant
Using tool X3, fill the air conditioner circuit with
[*2] the refrigerant (air conditioner gas: R134a).
3 Heater hose clamp: a Filling amount: 950 ± 50 g
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm} (per one air compressor)
a Two air compressors are used.
[*3]
a When installing the air conditioner circuit q Bleed air from the main pump, referring to
hoses, use care so that dirt, water may not "Bleeding air from each part" in Testing and
enter. adjusting.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
6 PC2000-8
Removal and installation of

engine, PTO and hydraulic pump
assembly 1
Removal
1. Remove power container assembly, referring
to "Removal and installation of power container
assembly."
2. Remove air cleaner upper cover (1).
3. Remove clamps (2), and then pull out 2 tubes

(3). [*1]
9. Disconnect connector A08 (12) and ground

TM1 (13) from the inside of emergency engine
stop switch – behind (SWB).
4. Remove hand rails (4).
5. Remove rear covers (5) and (6).

a SWB: Emergency engine stop switch –
behind 10. Disconnect connector L05B (14) from the bot-
tom of SWB.
11. Disconnect connector L08B (15).
12. Remove clip and disconnect harnesses (16).
6. Disconnect connector A07 (140) from the

backside of emergency engine stop switch –
front (SWF).
7. Remove front covers (7) and (8).
8. Remove upper covers (9) to (11).

a SWF: Emergency engine stop switch –
front
PC2000-8 7
13. Disconnect connector S27B (150) from back-

side of DSB (door switch - behind).
20. Disconnect 4 connectors (151) from the bot-

tom. P41A, P41B, P41C and P41D from the
14. Remove clips (17) and disconnect muffler top.
drain tubes (18).
21. Disconnect 4 connectors (152). P41A, P41B,
15. Remove clips (19) and disconnect muffler P41C and P41D from the top.
drain hoses (20).
22. Remove clip and disconnect harness (153).
16. Disconnect heater hoses (21) and (22).
23. Disconnect connectors L08A (154) and S27A

17. Disconnect 2 hoses (23). (155).
18. Disconnect brackets (24) and (25). 24. Remove clip and disconnect harness (156).
19. Remove clip and disconnect harnesses (26).
8 PC2000-8
25. Disconnect connector P24 (27). 31. Disconnect 2 air cleaner hoses (33). [*2]
26. Disconnect clips (28).
32. Lift and remove hood (34).

4 Hood assembly: 210 kg
27. Disconnect fan connector V18 (29).
28. Disconnect connectors M34 (30) and M35 (31)

from the compressor.
29. Disconnect harness (32).
30. Disconnect connector L13 (157) from the front

of machine in the pump room.
PC2000-8 9
33. Remove cover (35). 36. Remove bracket (38).

a Remove the opposite side at the same
34. Lift and remove muffler and bracket assembly procedures.
(36).
37. Temporarily lift air inlet duct assembly (39), and
lift and remove it.
4 Air inlet duct assembly: 450 kg
38. Remove 2 clamps (40).
39. Disconnect 2 tubes (41).
40. Remove clamp (42).
41. Disconnect tube (43).
42. Disconnect hose (44).
35. Remove dividing boards A, B and C (37)

between the engine room and pump room.
10 PC2000-8
43. Loosen clamps for hoses (45) to (47). [*3] 48. Disconnect 3 radiator lower hoses (51). [*5]
a Apply a marking to the hose end and tube
so that their original insertion positions
may be identified in later reference. (See
44. Remove dividing board (D) between the radia-

tor room and engine room.
45. Remove clamp bracket (48).
46. Disconnect 2 tube clamps (49). [*4]
47. Remove 2 tubes (50).

procedures. 49. Remove cover (52).
50. Disconnect 2 radiator upper hoses (53). [*6]
52. Temporarily lift cooling (radiator, aftercooler

and fan) assembly (55), and lift and remove it.
a Holes are provided on the top of the frame
for lifting.
4 Cooling (radiator, aftercooler and fan)
assembly: Approx. 1,200 kg
PC2000-8 11
53. Disconnect 2 tube clamps (56). 60. Disconnect hoses (64), (65) and (66).
61. Disconnect 4 hoses (67).
62. Disconnect hose clamp (68).
63. Disconnect 2 hoses (69) and 2 hoses (70) from

the fuel pre-filter.
64. Disconnect rear cover (71).
55. Disconnect tube clamp (58).
65. Disconnect frame (72) in which rear covers

(63) and (71) were attached, from the frame
assembly (73).
58. Disconnect 3 hoses (61) and 3 hoses (62) from

the filter.
59. Disconnect rear cover (63).
66. Remove bracket (74).
12 PC2000-8
67. Remove mounting bolt, and then lift and 74. Disconnect fuel hoses (79), (80) and (81) from
remove frame assembly (73). the rear of the container.
4 Frame assembly: 270 kg
75. Remove brackets (82) and (83).
76. Disconnect engine ground (84).
77. Disconnect radiator pipe (85).

a Do not disconnect air conditioner hose
(AH).
70. Loosen adjustment nut (170) of the air condi-
tioner compressor.
72. Remove air conditioner compressor belts (78).

[*7]
73. Remove 2 air conditioner compressors (171).
79. Disconnect hose (87) from the No.1 main

pump.
PC2000-8 13
83. Disconnect connectors V12 (91) and V11 (93) 87. Disconnect suction tube (95) from the No.1
from inside the No.1 main pump. main pump.
84. Disconnect harness (94). 88. Disconnect 3 hoses (96), (97) and (98) from
the fan pump (middle lower).
85. Disconnect connectors V15 (161) and V16

(162) from the fan pump (middle lower). 89. Disconnect hose P34 (100) from the fan pump
(middle lower).
91. Disconnect hoses (102) to (105).
86. Disconnect connector P35 (163) from the fan

pump (middle lower).
92. Disconnect fan motor connector V17 (106).
14 PC2000-8
94. Disconnect connectors V14 (110) and V13 100.Remove cover (119).
(111) from the No. 2 main pump.
101.Disconnect connectors (120). VH16, VH17,
95. Disconnect harnesses (112) and (113). VH18 and VH19 from the left.
96. Disconnect 2 hoses (114). 102.Disconnect terminal (121).
103. Remove clips and disconnect 2 harnesses (122).

a Clamps are attached to the hoses. 104.Disconnect connectors PIM (123) and TIM
(124).
105.Disconnect connectors (125) and E01 (126).
106.Disconnect connector CNRP (127).
107.Remove clips and disconnect 2 harnesses

(128) and (129).
98. Remove engine controller cover (116).
99. Disconnect connectors CE05 (117) and CE08

(118) from the engine controller. [*8]
procedures.
PC2000-8 15
108.Disconnect clips (130). 113. Temporarily lift engine, PTO and pump assem-
bly.
109.Disconnect 2 harnesses (131) from the starting Rear side fulcrum (right and left of PTO upper
motor. area): RP
Front side fulcrum: FP
110. Disconnect harness (132) from the starting
motor.
114. Remove engine, PTO and pump assembly

(136) mount bolts. [*9]
111. Disconnect connector P19 (133) from the PTO Pump side mount bolt: (135)
oil pan. Radiator side mount bolt: MB
112. Disconnect clips (134) from the bottom of PTO. 115. Lift and remove engine, PTO and pump
assembly (136).
4 Engine, PTO and pump assembly:
Approx. 6,100 kg
16 PC2000-8
Installation [*7]
q Carry out the installation in the reverse order of q Adjust air conditioner compressor belt tension,
removal. referring to "Testing and adjusting: Adjusting
air conditioner compressor belt tension."
[*1]
3 Hose clamp of Komaclone tube assembly: [*8]
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm} q Make sure inside (particularly the bottom) of
the controller connector is free from sands,
[*2] dusts or water. If such foreign substances are
3 Air cleaner hose clamp: present, clean them completely with the air
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} blow. (Sands, dusts or water can cause defect
contact or allow commingling of water.)
[*3]
q Air hose [*9]
a Use new MIKALOR clamp. a Note that the washer (U) in upper position is
1) Align the hose to the original position (marked different from the (D) in lower position on the
position). (Air hose insertion depth: Min. 80 mm) radiator side.

q When a new hose is used

4) Tighten the bolt until BDG dimension meets 3 Engine mount bolt:
the following. 824 – 1030 Nm {84 – 105 kgm}
BDG: 17 – 20 mm Target: 927 Nm {94.5 kgm}
[*4]
3 Air tube clamp: 21 Nm {2.55 kgm}
[*5]
3 Radiator hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*6]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
PC2000-8 17

radiator assembly 1
Removal
1. Remove clamp and drain coolant from the
hose (1).
6 Coolant: 180 l
2. Disconnect 3 radiator outlet hoses (2). [*1]

a Three radiators are provided.
3. Remove hand rail (3).
4. Remove radiator upper cover (4).

Installation
q Carry out installation in the reverse order to
removal.
[*1], [*2]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
again.
5 Coolant: 180 l
5. Disconnect reservoir tank hose (5).
6. Disconnect radiator inlet hoses (6). [*2]
7. Remove brackets (7) (2 pieces for each radia-

tor).
8. Raise and remove radiator assembly (8).

4 Radiator assembly:
Approx. 25 kg (each)
18 PC2000-8
Removal and installation of 4. Remove bracket (4).

aftercooler assembly 1
procedures.
Removal
1. Remove hand rail (1). 5. Temporarily lift air inlet duct assembly (5), and
lift and remove it.
2. Remove radiator side cover (2).
procedures.
3. Remove radiator upper cover (3).
6. Remove lower bracket (6).
7. Remove air tube clamp (7). [*1]

a Loosen tube clamp inside the engine
room.
8. Disconnect aftercooler hoses (8) and (9). [*2]

9. Lift air aftercooler (11) temporarily.
10. Remove upper brackets (10).
11. Lift and remove aftercooler assembly (11) by

lifting both sides.
4 Aftercooler assembly: 45 kg (one side)
PC2000-8 19
Installation
q Carry out the installation in the reverse order of
removal.
[*1]
[*2]
q Air hose
a Use new MIKALOR clamp.
1) Align the hose to the original position (marked
position). (Air hose insertion depth: Min. 80 mm)


4) Tighten the bolt until BDG dimension meets
the following.
BDG: 17 – 20 mm
20 PC2000-8

hydraulic oil cooler assembly 1
Removal
k Loosen the oil filler cap gradually to release
the internal pressure of the hydraulic tank
1. Drain hydraulic oil.

6 Hydraulic tank: 1,300 l

a Prepare a container and oil plug to catch
oil leaks.
3. Remove hydraulic oil cooler upper cover (5).

Installation
removal.
q Refilling with oil (Hydraulic tank)

Add oil through oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
4. Remove cover (6) and disconnect oil cooler

upper hose (7).
6. Lift and remove hydraulic oil cooler assembly

(9).
4 Hydraulic oil cooler assembly:
170 kg (each side)
PC2000-8 21
Removal and installation of fuel Installation

cooler assembly 1
removal.
Removal
1. Close fuel tank valve.
2. Remove hydraulic oil cooler air inlet duct

assembly (1).
3. Disconnect hoses (3) and (4).

a Use a double spanner (its reactive force)
when removing the fuel hose. (To prevent
damaging weld on the fuel cooler.)
a Prepare a plug and container to catch fuel.
4. Remove fuel cooler assembly (5).
22 PC2000-8
Removal and installation of Radiator side

cooling assembly 1 7. Disconnect 3 radiator lower hoses (9). [*1]
Removal
1. Remove power container assembly, referring
to "Removal and installation of power container
assembly."
3. Remove side covers (2) and (3).

a SWB: Emergency engine stop switch –
behind

procedures.

lift and remove it.
4. Disconnect connector A07 (50) from the back-

side of emergency engine stop switch – front
(SWF).
5. Remove side covers (4) and (5).
6. Remove upper covers (6) to (8).

a SWF: Emergency engine stop switch –
front
10. Disconnect fan motor connector V18 (12).
PC2000-8 23
11. Remove 2 clamps (13).
12. Disconnect 2 tubes (14).
22. Disconnect 2 radiator upper hoses (25). [*4]
16. Loosen clamps for hoses (18) to (20). [*2]

17. Remove dividing board (D) between the radia-

tor room and engine room.

24. Temporarily lift cooling (radiator, aftercooler
19. Disconnect 2 tube clamps (22). [*3] and fan) assembly (27), and lift and remove it.
a Holes are provided on the top of the frame
20. Remove 2 tubes (23). for lifting.
procedures. 4 Cooling (radiator, aftercooler and fan)
24 PC2000-8
Oil cooler side 27. Remove 2 hoses (33).

lift and remove it. 28. Disconnect 2 tube clamps (34).
4 Air inlet duct assembly : 450 kg

26. Remove cover (31) and disconnect oil cooler
upper hose (32). 30. Disconnect tube clamp (36).
a Disconnect both sides.
31. Disconnect fan connector V17 (37).
PC2000-8 25
33. Remove fuel tubes (41) from the fuel cooler Installation
(FC). q Carry out the installation in the reverse order of
a Use a double spanner and avoid applying removal.
force to the fuel cooler (aluminum weld
portion) when removing the fuel tube. [*1]
34. Temporarily lift cooling (oil cooler, fuel cooler 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
and fan) assembly (42), and lift and remove it.
a Holes are provided on the top of the frame [*2]
for lifting. q Air hose
a
4
Use new MIKALOR clamp.
Cooling (radiator, fuel cooler and fan)
position). (Air hose insertion depth: Min. 80 mm)


the following.
BDG: 17 – 20 mm
[*3]
[*4]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
26 PC2000-8
Removal and installation of fan

motor assembly 1
Removal
1. Remove cooling assembly, referring to
"Removal and installation of cooling assem-
bly."
2. Remove fan guards (1) and (2).
3. Remove fan guards (3) and (4). (Radiator side

only)
4. Remove cover (5). (Radiator side only)

9. Remove fan motor assembly (13) from the
5. Remove oil tubes (6) and (7) for fan motor. bracket assembly (12).
(Radiator side only) a Be careful with the key (K).
a Radiator side cooling assembly is shown
in the picture.
Installation
6. Remove fan bracket assembly (8) from the removal.
cooling assembly.
4 Fan bracket assembly: Approx. 180 kg [*1]
When aligning the bolt hole of the lock plate, turn
the nut in the retightening direction.
7. Remove lockplate (9). [*1]
[*2]
8. Remove bolt (10), and then remove fan a Degrease the hole and shaft before installing
assembly (11). [*2] the fan assembly.
a Use a puller to remove the fan assembly. a Use a bar to fix the fan assembly to tighten the
Do not hit it with a hammer. nut.
3 Fan assembly mounting nut:
a Be careful with the key (K).
q Initial tightening torque:
932 – 981 Nm {95 – 100 kgm}
q Tightening torque median value:
956 Nm {97.5 kgm}
a After tightening, use both sides of the lock
plate to align the lock plate bolt hole and
retighten the nut by the minimum angle.
(Allowable retightening angle: Max. 15°)
PC2000-8 27
Removal and installation of fuel 6. Disconnect fuel hoses (8) from the top rear of
tank assembly 1
the fuel tank.
Removal 7. Disconnect clamp (9).

1. Drain fuel.
5 Fuel tank: 3,500 l (at full)
3. Remove decks (2) and (3).

4 Deck assembly (2): Approx. 240 kg
4 Deck assembly (3): Approx. 400kg
a Right side deck of the container has been
removed in the picture.
8. Disconnect connector A24 (10) from the bot-

tom rear (A) of the fuel tank.
4. Disconnect fuel supply hose (5) and fuel drain

hose (4) from the bottom of the fuel tank.
5. Disconnect fuel stop cable (6).

9. Remove 10 mounting bolts (12) from both
sides. [*1]
10. Lift and remove fuel tank assembly (13).

4 Fuel tank assembly: Approx. 2,100 kg
28 PC2000-8
Installation
removal.
[*1]
3 Fuel tank mounting bolt:
1,520 – 1,910 Nm {155 – 195 kgm}
PC2000-8 29
SEN02134-00
© 2006 KOMATSU
All Rights Reserved
30
SEN02135-00
PC2000-8

PC2000-8 20001 and up
Engine (12V140E-3)
Engine (12V140E-3) ....................................................................................................................................... 2
Removal and installation of fuel supply pump assembly...................................................................... 2
Removal and installation of cylinder head assembly ........................................................................... 5
Removal and installation of fuel injector............................................................................................. 18
Removal and installation of engine front seal .................................................................................... 28
Removal and installation of engine rear seal ..................................................................................... 31
PC2000-8 1
Engine (12V140E-3) 1
Removal and installation of fuel 3. Remove fuel filter (4).

supply pump assembly 1
a Use a filter wrench or others to remove the
filter.
Removal
k Lower the work equipment completely to 4. Remove fuel return hose and tube assembly
the ground and stop the engine. (5) from the common rail system. [*1]
k Lock the work equipment lock lever.
k Disconnect the negative terminal (–) of the 5. Disconnect fuel return hose (6). [*2]
battery.
6. Remove fuel tube (7) and fuel tube and hose
1. Close the fuel valve through the bottom of fuel assembly (8). [*3]
tank.
a The figure shows the left bank side. 7. Disconnect bracket (9).
Repeat the same procedure at the right
bank side. 8. Remove 4 right and left rubber covers (10).
2. Disconnect connectors PCV1 (1), PCV2 (2) 9. Remove high-pressure pipe clamp assembly
and G (3). (11).
10. Remove high-pressure pipe assembly (12).
11. Disconnect fuel hose (13). [*4]
12. Remove lubrication tube (14).
14. Remove mounting bolts (19), and then remove

fuel supply pump assembly (16).
2 PC2000-8
Installation High-pressure piping

1. Temporarily install supply pump assembly (16). k When handing the high-pressure pip-
2 Supply pump assembly mounting bolts: ing and clamp, pay attention to the fol-
Adhesive (LT-2) lowing.
a Insert supply pump by aligning unequal q It is strictly prohibited to bend the
spline section (A) at the supply pump drive high-pressure piping to use it again or
case to the unequal spline section of sup- using it in other locations.
ply pump shaft. q Install the specified clamp securely in
a If it is difficult to insert the supply pump the specified position with the speci-
into the port, slightly rotate the crankshaft fied torque.
and change the position of unequal spline q Don't apply lubricant and the like to
section (A). the high-pressure piping sleeve nut
a After having tightened the sleeve nuts on and the threaded portion of the mat-
the high-pressure pipe (between the fuel ing side.
supply pump and common rail section), a Axial force in the tightening can be
tighten the mounting bolts with the speci- excessive, potentially damaging
fied torque. the high-pressure piping.
k Before installing the high-pressure pip-
ing, check it for the following defects.
If there is any of these defects, it can
c a u s e f u e l l e a k a g e . A c c o r di n gl y,
replace the high-pressure piping.
q Check the taper seal of the connect-
ing part (Part (a): Part of 2 mm from
the end) for visible lengthwise slit (b)
and dent (c).
q Check part (d) (end of the taper seal:
Part at 2 mm from the end) for
stepped-type wear (fatigue) which
your nail can feel.
PC2000-8 3
2. Install the high-pressure pipe in the following

procedure.
1) Temporarily install high-pressure pipe
assembly (12) and tighten its sleeve nuts
with the specified torque.
a Use a commercially available
(knuckle type) torque wrench to
tighten nuts with the correct torque.
3 Sleeve nuts on the high-pressure
pipe (fuel supply pump side):
39.2 – 49 Nm {4 – 5 kgm}
pipe (common rail system side):
39.2 – 58.8 Nm {4 – 6 kgm}
2) Tighten the fuel supply pump assembly q Carry out the following installation in the
mounting bolts. reverse order of removal.
3) To avoid the excessive tightening of the
supply pump assembly, loosen mounting [*1], [*2], [*3]
bolt (17) of bracket (15). 3 Joint bolts at fuel supply pump side:
4) Tighten bracket (15) and mounting bolts 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(17) and (18) alternately.
3 Mounting bolt (17): [*4]
59 – 74 Nm {6.0 – 7.5 kgm} 3 Joint bolts at filter (top) side of fuel hose
3 Mounting bolt (18): (13): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
19.6 – 29.4 Nm {2.0 – 3.0 kgm} 3 Joint bolts at fuel supply pump side:
5) Install lubrication tube (14). 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Lubrication tube joint bolts: a The fuel tube is used instead of fuel hose (13)
9.8 – 12.7 Nm {1.0 – 1.3 kgm} in the right bank section.
6) Install high-pressure pipe clamp (11) as
follows.
1] Manually tighten both high-pressure
pipe clamp (11) and bracket (9) for
temporary installation.
2] Tighten clamp (11) permanently.
a Tighten the bolts carefully to pre-
vent excessive force to the
mounting section of supply pump
assembly.
3 Clamp bolts:
9.8 ± 1 Nm {1 ± 0.1 kgm}
3] Tighten bracket (9) permanently.
7) Install 4 rubber covers (10) onto sleeve
k
nuts of high-pressure pipe.
Make sure that a clearance of 10 mm mini-
a Direct the slit section as follows dur-
mum is provided between the high-pres-
ing installation.
sure piping and adjacent wiring harness. If
q Fuel supply pump side: Down-
not, secure the clearance by adjusting the
ward
wiring harness position.
q Common rail system side: Inward
(in opposite direction)
q Bleeding air
Bleed air from the fuel system, referring to
“Bleeding air from fuel system” in Testing and
adjusting.
4 PC2000-8

cylinder head assembly 1
Special tool
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
A 1 790-331-1110 Wrench q 1
Removal
k Lock the work equipment lock lever. 2. Close the fuel valve through the bottom of fuel
k Disconnect the negative terminal (–) of the tank.
battery.
3. Disconnect the right and left air cleaner hoses
1. Disconnect and remove the following primary (4). [*1]
components, referring to Steps 1 – 37, 44 – 48,
and 54 – 68 of "Removal of engine, PTO and 4. Remove cover (5).
hydraulic pump assembly."
q Disconnect cable connectors and wiring 5. Disconnect connectors P41A, P41B, P41C
harnesses of the container assembly. and P41D from the left, and then disconnect
q Engine hood (1) wiring harness (6).
q Muffler and bracket assembly (2)
q Disconnect hoses around the oil filter. 6. Remove plate (5-1) from the intake manifold.
q Air hoses between air aftercooler and
engine: Total 4 pieces 7. Disconnect wiring harness (7).
q Frame and air cleaner assembly (3)
8. Disconnect connectors PIM (8-1) and TIM (8-
a Check whether all hose clamp and others 2).
is disconnected.
PC2000-8 5
q Right bank (back side of machine)

q Left bank
a Fuel hose (10-1) faces downward in the 14. Remove clamp (16).
right bank section.
15. Disconnect fuel tube (17). [*3]
11. Disconnect connectors (11), (12) and (13) from
sockets of engine controller (EC). [*2] 16. Remove fuel filter assembly (18).
12. Disconnect wiring harness (14). 17. Disconnect fuel hose (19). [*3]
13. Remove engine controller, cooler and bracket 18. Disconnect and remove fuel tube (20).
assembly (15).
a E: Ground cable
6 PC2000-8
q Right bank 30. Remove bracket assembly (32). [*4]
19. Remove the clamp and then remove fuel tube

(21). [*3]
21. Disconnect and remove fuel tube (23).
31. Remove air intake connector (33). [*5]

a Remove the RH: electrical intake air
heater, too.
a Remove the harness clamp.
22. Disconnect wiring harness (24).
23. Remove fuel filter assembly (25).
24. Remove oil tube (26).
25. Remove oil filter assembly (27).
27. Remove air tube (29).

32. Remove spill tube (34). [*6]
28. Remove thermal insulation cover (30).
29. Remove stay (31).

a Disconnect the harness clamp.
PC2000-8 7
33. Remove bracket (35). 41. Remove rubber covers (44) and (45).
34. Remove clamps (36) and (37).
35. Remove high-pressure pipe (38). 42. Remove high-pressure pipes (46).
43. Remove intake manifold (47).

37. Remove clamp (40). 4 Intake manifold: 35 kg
38. Remove brackets (41-1) to (41-7) from the bot-

tom of intake manifold.
40. Remove brackets (43-1) to (43-3) from the top

of intake manifold.
a Remove the brackets and clamps similarly
from the left bank section.
44. Remove exhaust tube (48).
46. Remove exhaust connector (50).
47. Remove exhaust connector and bracket

assembly (51).
8 PC2000-8
48. Remove the following parts and components 52. Remove the external wiring harness of injector.
from the turbocharger (TC) unit. 1) Remove cover plate (58).
q Lubrication tube (52) 2) Disconnect harness connector (59) from
q Lubrication drain tube (53) each cylinder head, and then disconnect
q Coolant tube (54) [*7] wiring harness (60).
q Coolant hose (55) [*7]
53. Remove air vent tubes (61) and (62). [*9]
54. Remove spill tube (63).
55. Remove head cover (64).
49. Remove thermal insulation cover (56).
50. Temporarily lift turbocharger (TC) and exhaust

manifold assembly (57), and remove the
mounting bolts. [*8]
51. Lift and remove turbocharger and exhaust

manifold assembly (57).
4 Turbocharger and exhaust manifold
assembly: 60 kg
PC2000-8 9
56. Removal of rocker arm assembly 5) Insert a small L-shaped bar [B] to the bot-
1) Loosen locknut (65), and fully loosen tom of the fuel connector, and then pull out
adjustment screw (66). the fuel injector (75) using the leverage.
a Check that the rocker arm has no a Do not pull out the solenoid valve
valve tension and it is in free status. section at the top of the fuel injector,
2) Remove rocker arm assembly (67). using a tool such as pliers.
a Record the assembly installation
position using luggage tag for identifi-
cation, and place the assembly in
storage.
60. Lift and remove cylinder head assembly (76).

4 Cylinder head assembly: 30 kg
a When removing the cylinder head assem-
57. Remove pushrod (68). bly with the fuel injector being installed,
the top end of injector extends from the
58. Remove crosshead (69). cylinder head bottom section. Thus,
install appropriate blocks on the floor to
59. Removal of fuel injector prevent interference to the floor surface.
1) Remove injector terminal mounting nuts
(70).
2) Remove clamp mounting bolt (71).
3) Push harness connector (72) into the cyl-
inder head, and remove injector harness
(73).
4) Remove holder mounting bolt (74).
61. Remove the cylinder head gasket.
10 PC2000-8
Installation a For retightening, use tool A1 (see Special

tools). When not using tool A1, apply a
Cylinder head assembly marking to the cylinder head and bolt with
a felt pen and then retighten the bolt by 90
1. Install the cylinder head gasket. – 120° (target is 120°).
2. Lift and install cylinder head assembly (93).

4 Cylinder head assembly: 30 kg
a After tightening the main bolt, apply a

punch mark (a) on its head (this mark shall
not be applied to a new bolt).
a Check the punch mark on the mounting

bolt head. If 5 marks are punched, replace
it with a new one without using it.
a Length of mounting bolts:
(1), (2), (4): 166 mm
(3), (5), (6): 201 mm
a Tighten the mounting bolts in the following
order.
2 Cylinder head assembly mounting bolt:
Molybdenum disulfide grease (LM-P)
3 Cylinder head assembly mounting bolts
(1 – 6):
1st time: 137 – 157 Nm {14 – 16 kgm}
2nd time: 284 – 294 Nm {29 – 30 kgm}
3rd time: 90 – 120° retightening
3 Cylinder head assembly mounting bolts
(7): 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
PC2000-8 11
Fuel injector Crosshead

a Check that the inside of the injector sleeve is 7. Install crosshead (69).
free from dirt. 2 Crosshead sliding surface:
2 O-ring: Engine oil (EO30) Engine oil (EO30)
3. Assemble O-rings (77) and (78) to fuel injector

(75).
a Take care not to install O-ring (78) in
groove (A) at the center.
4. Assemble gasket (79) to fuel injector (75).
5. Insert fuel injector (75) to cylinder head with

injector holder (80).
8. Adjust the crosshead in the following proce-

dure.
1) Loosen locknut (102) and then loosen
adjustment screw (103) to a position
where it does not touch valve stem (104).
2) Maintain the contact with valve stem (105)
on the push rod side by pressing the con-
tact face against the rocker arm using a
finger.
3) Tighten adjustment screw (103) to confirm
the position where adjustment screw (103)
6. Attach spherical washer (81) to bolt (74) and is contacted against valve stem (104).
then tighten injector holder (80) temporarily. 4) Drive in adjustment screw (103) further by
2 Ball washer: Engine oil (EO30) 20 – 30° from the contacting position
a Tightening of injector holder (80) is done against valve stem (104).
permanently after installing the intake 5) Tighten locknut (102) while suppressing
manifold and tightening the high-pressure move of adjustment screw (103).
piping temporarily. 3 Locknut:
58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}
12 PC2000-8
9. Injector harness
1) Push out harness connector (72) from
inside to outside of cylinder head, and
install injector harness (73) inside of the
cylinder head.
2) Tighten injector terminal mounting nuts
(70) and clamp mounting bolt (71).
a Tighten injector terminal mounting
nuts (70) alternately.
3 Injector terminal mounting nuts:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a After having tightened the injector ter-
minal mounting nuts, eliminate sag on
the wiring harness and secure it to
the injector main unit. 3 Locknuts:
52.9 – 64.7 Nm {5.4 – 6.6 kgm}
10. Install pushrod (68). a After having tightened the locknut, check
a Check that the end of pushrod is securely the valve clearance again.
engaged with the holder section of cam
follower.
2 Both ends of pushrod:
Engine oil (EO30)
12. Install spill tube (63).

3 Joint bolts:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
11. Install the rocker arm assembly. 13. Install head cover (64). (This is necessary to
2 Rocker arm shaft: Engine oil (EO30) prevent dust insertion into cylinders. Remove
2 Rocker arm assembly mounting bolt the cylinder head cover later.)
threads and washer: EO30 engine oil
a Check that the ball section of adjustment
screw (66) is securely placed in the socket
of pushrod.
a When tightening the bolt, check that
adjustment screw (66) does not press the
pushrod.
2 Rocker arm assembly mounting bolts:
93 – 103 Nm {9.5 – 10.5 kgm}
a Adjust the valve clearance, and then
tighten locknut (65).
a Adjust the valve clearance, referring to
"Checking and adjusting valve clearance"
of Testing and adjusting.
PC2000-8 13
14. Fuel injector and high-pressure piping 1) Install O-ring (83) on sleeve nut (82).
(Between common rail and fuel injector) 2 O-ring: Engine oil (EO30)
k When handing the high-pressure pip- 2) Tighten sleeve nut (82) on fuel injector
ing and clamp, pay attention to the fol- (75) temporarily.
lowing. a If it is difficult to mount sleeve nut (82)
q It is strictly prohibited to bend the onto the threads of mount, push the
high-pressure piping to use it again or end of sleeve nut (82) toward the
using it in other locations. injector using the rod. Then rotate the
q Install the specified clamp securely in nut using a wrench.
the specified position with the speci- 3) Temporarily tighten sleeve nut (84) at the
fied torque. common rail section, too.
q Don't apply lubricant and the like to 4) Tighten and secure injector holder (80)
the high-pressure piping sleeve nut permanently.
and the threaded portion of the mat- 3 Injector holder mounting bolt (74):
ing side. 58.9 – 73.5 Nm {6.0 – 7.5 kgm}
a Axial force in the tightening can be 5) Tighten the sleeve nut with the specified
excessive, potentially damaging torque.
the high-pressure piping. a Use a commercially available (knuckle
k Before installing the high-pressure pip- type) torque wrench to tighten nuts
ing, check it for the following defects. with the correct torque.
If there is any of these defects, it can 3 Sleeve nuts on high-pressure pipe
c a us e f u e l l e a k a g e. A c c o r d i n gl y, (46) at injector side:
replace the high-pressure piping. 39.2 – 49 Nm {4 – 5 kgm}
q Check the taper seal of the connect- 3 Sleeve nuts on high-pressure pipe
ing part (Part (a): Part of 2 mm from (46) at common rail system side:
the end) for visible lengthwise slit (b) 39.2 – 49 Nm {4 – 5 kgm}
and dent (c). a After having tightened the nuts, check
q Check part (d) (end of the taper seal: that O-rings (77) and (83) do not pro-
Part at 2 mm from the end) for trude from sleeve nut (82).
your nail can feel.
14 PC2000-8
6) Install the cylinder head cover. 16. Install the high-pressure pipe clamp (between
3 Cylinder head cover mounting the common rail system and fuel injector) in
bolts: the following procedure.
14.7 – 34.3 Nm {1.5 – 3.5 kgm} 1) Manually tighten brackets (41-1) to (41-7)
7) Install rubber covers (44) and (45) on the and clamp (42) from the bottom of intake
sleeve nuts of high-pressure pipe (46). manifold for temporary installation.
a Direct the slit section as follows dur- 2) Also, manually tighten brackets (43-1) to
ing installation. (43-3) and clamp from the top of intake
q Injector side (44): Downward manifold for temporary installation.
q Common rail system side (45): 3) Tighten the top and bottom clamps perma-
Toward the cylinder block nently.
3 Top and bottom clamp bolts:
9.8 ± 1.0 Nm (1.0 ± 0.1 kgm}
4) Tighten brackets (41-1) to (41-7) and (43-
1) to (43-3) permanently.
5) Temporarily tighten clamp (40) and
bracket (39), and then tighten them per-
manently.
a Bracket (39): See the figure next
page.
3 Mounting bolts for bracket (39):
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
a Install the brackets and clamps simi-
larly in the left bank section.
15. Intake manifold assembly

1) Install the gasket.
a Face the side with "UP" mark upward,
and install the gasket so that the UP
side directs to the intake manifold.
2 Mounting bolt threads and washer:
Molybdenum disulphide lubricant
(LM-P)
a Tighten the mounting bolts in the pro-
cedure shown in the figure.
3 Intake manifold mounting bolts:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
PC2000-8 15
17. High-pressure pipe (between the common rail q Carry out the following installation in the
system and fuel supply pump) reverse order of removal.
a For precaution for installation, refer to
"High-pressure pipe (between the com- [*1]
mon rail system and fuel supply pump)." 3 Air cleaner hose clamps:
a Use a commercially available (knuckle 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
type) torque wrench to tighten nuts with
the correct torque. [*2]
1) Temporarily tighten high-pressure pipe q Make sure inside (particularly the bottom) of
(38), and then tighten it permanently. the controller connector is free from sands,
3 Sleeve nuts on the high-pressure dusts or water. If such foreign substances are
pipe (common rail system side): present, clean them completely with the air
39.2 – 58.8 Nm {4 – 6 kgm} blow. (Sands, dusts or water can cause defect
3 Sleeve nuts on the high-pressure contact or allow commingling of water.)
pipe (fuel supply pump side):
39.2 – 49 Nm {4 – 5 kgm} [*3]
2) Manually tighten bracket (35) and clamps 3 Fuel tube joint bolts:
(36) and (37) for temporary installation. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3) Tighten high-pressure pipe clamps (36) 3 Fuel hose joint bolts:
and (37) permanently. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 High-pressure pipe clamp bolts:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} [*4]
4) Tighten high-pressure pipe bracket (35) 3 Bracket assembly mounting bolts:
permanently. 49 – 68.6 Nm {5.0 – 7.0 kgm}
[*5]
3 Air intake connector mounting bolts:
49 – 68.6 Nm {5.0 – 7.0 kgm}
[*6]
3 Spill tube joint bolts
Cylinder head side:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
Intake manifold side:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*7]
3 Turbocharger coolant tube joint bolts (upper
side): 24.5 – 34.3 Nm {2.3 – 2.5 kgm}
3 Turbocharger coolant tube sleeve nuts
(lower side): 24.5 – 59 Nm {2.3 – 6.0 kgm}
3 Turbocharger coolant hose:
29.4 – 39.2 Nm {3.0 – 4.0 kgm}
16 PC2000-8
[*8]
Exhaust manifold assembly
1) Install the gasket.
a Face the side with "OUT" mark to the exhaust
manifold during installation.
a Tighten the mounting bolts in the procedure
shown in the figure.
a After having tightened all bolts, retighten them
with the same torque.
2 Mounting bolt threads and washer:
Molybdenum disulphide lubricant (LM-P)
3 Exhaust manifold mounting bolts:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
Reference
Turbocharger assembly
2 Turbocharger assembly mounting bolts and
nuts:
Molybdenum disulphide lubricant (LM-P)
3 Turbocharger assembly mounting bolts:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
[*9]
3 Air vent tube mounting bolts:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
again.
5 Coolant: 180 l
k Make sure that a clearance of 10 mm mini-

mum is provided between the high-pres-
sure piping and adjacent wiring harness. If
not, secure the clearance by adjusting the
wiring harness position.
q Bleeding air
Bleed air from the fuel system, referring to
“Bleeding air from fuel system” in Testing and
adjusting.
PC2000-8 17
Removal and installation of fuel 5. Disconnect connector A07 (100) at the rear of
injector 1
front side of emergency engine stop switch
(SWF).
Removal
k Lower the work equipment completely to 6. Remove front cover (5).
the ground and stop the engine. a SWF: Front side of emergency engine
k Lock the work equipment lock lever. stop switch
k Disconnect the negative terminal (–) of the
battery. 7. Remove top covers (6) and (7).
1. Close the fuel valve through the bottom of fuel

tank.
2. Remove air cleaner top cover (1).
3. Remove clamps (2), and disconnect 2 tubes

(3). [*1]
8. Disconnect connector (8) and ground connec-

tor TM1 (9) from the inside of rear side of
emergency engine stop switch (SWB).
4. Remove rear cover (4).

a SWB: Rear side of emergency engine
stop switch
9. Disconnect connector L05B (10) from the bot-

tom of SWB.
18 PC2000-8
10. Lift and remove engine hood (12). 14. Remove clip (17) and disconnect muffler drain
tube (18).
15. Remove clip (19) and disconnect muffler drain

hose (20).
16. Remove stay (21).

a Remove the stay from rear side, too.
11. Disconnect connector S27R (13) from the rear

panel of rear door switch DSB.
17. Disconnect 2 air cleaner hoses (22). [*2]
q Front side
12. Disconnect connectors L08A (14) and S27A
(15).
13. Remove clips and disconnect wiring harness

(16).
PC2000-8 19
18. Loosen hose clamps (23) to (25). [*3] q Left bank section
a Apply a marking to the hose end and tube 22. Remove clamp (29).
may be identified in later reference. (See 23. Disconnect fuel tube (30). [*5]
20. Remove 2 tube clamps (27). [*4]
26. Disconnect fuel tube (33).
a Remove the tubes from the opposite side,
too.
q Right bank section

27. Remove clamps and disconnect fuel tube (34).
[*5]
29. Disconnect fuel tube (36).
30. Disconnect wiring harness (37).
32. Remove oil tube (39).
33. Remove oil filter assembly (40).
35. Disconnect air tube (42).
20 PC2000-8
36. Remove bracket assembly (43). [*6] 42. Remove clamp (50).
43. Remove brackets (51-1) to (51-3) from the bot-

tom of intake manifold.
45. Remove brackets (53-1) to (53-3) from the top

of intake manifold.
a Remove the brackets and clamps similarly
from the left bank section.
37. Remove air intake connector (44). [*7]

a Remove the RH: electrical intake air
heater with together.
a Remove the harness clamp.
39. Remove clamps (46) and (47).
40. Disconnect high-pressure pipe (48).

46. Remove rubber covers (54) and (55).
47. Disconnect high-pressure pipes (56).
PC2000-8 21
48. Disconnect the external wiring harness of 51. Removal of fuel injector
injector. 1) Remove injector terminal mounting nuts
1) Remove cover plate (58). (70).
2) Disconnect harness connector (59) from 2) Remove clamp mounting bolt (71).
each cylinder head, and then disconnect 3) Push harness connector (72) into the cyl-
wiring harness (60). inder head, and remove injector harness
49. Remove head cover (61). (73).
4) Remove holder mounting bolt (74).
50. Removal of rocker arm assembly

1) Loosen locknut (65), and fully loosen 5) Insert a small L-shaped bar [B] to the bot-
adjustment screw (66). tom of the fuel connector, and then pull out
a Check that the rocker arm has no the fuel injector (75) using the leverage.
valve tension and it is in free status. a Do not pull out the solenoid valve
2) Remove rocker arm assembly (67). section at the top of the fuel injector,
a Record the assembly installation using a tool such as pliers.
position using luggage tag for identifi-
cation, and place the assembly in
storage.
22 PC2000-8
Installation 5. Injector harness

1) Push out harness connector (72) from
Fuel injector inside to outside of cylinder head, and
a Check that the inside of the injector sleeve is install injector harness (73) inside of the
free from dirt. cylinder head.
2 O-ring: Engine oil (EO30) 2) Tighten injector terminal mounting nuts
(70) and clamp mounting bolt (71).
1. Assemble O-rings (77) and (78) to fuel injector a Tighten injector terminal mounting
(75). nuts (70) alternately.
a Take care not to install O-ring (78) in 3 Injector terminal mounting nuts:
groove (A) at the center. 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a After having tightened the injector ter-
2. Assemble gasket (79) to fuel injector (75). minal mounting nuts, eliminate sag on
the wiring harness and secure it to
3. Insert fuel injector (75) to cylinder head with the injector main unit.
injector holder (80).
4. Attach spherical washer (81) to bolt (74) and

then tighten injector holder (80) temporarily.
2 Ball washer: Engine oil (EO30)
a Tightening of injector holder (80) is done
permanently after installing the intake
manifold and tightening the high-pressure
piping temporarily.
PC2000-8 23
6. Install the rocker arm assembly. 8. Fuel injector and high-pressure piping
a Check that the ball section of adjustment (Between common rail and fuel injector)
screw (66) is securely placed in the socket k When handing the high-pressure pip-
of pushrod. ing and clamp, pay attention to the fol-
a When tightening the bolt, check that lowing.
adjustment screw (66) does not press the q It is strictly prohibited to bend the
pushrod. high-pressure piping to use it again or
2 Rocker arm shaft: Engine oil (EO30) using it in other locations.
2 Rocker arm assembly mounting bolt q Install the specified clamp securely in
threads and washer: EO30 engine oil the specified position with the speci-
2 Rocker arm assembly mounting bolts: fied torque.
93 – 103 Nm {9.5 – 10.5 kgm} q Don't apply lubricant and the like to
a Adjust the valve clearance, and then the high-pressure piping sleeve nut
tighten locknut (65). and the threaded portion of the mat-
a Adjust the valve clearance, referring to ing side.
"Checking and adjusting valve clearance" a Axial force in the tightening can be
of Testing and adjusting. excessive, potentially damaging
the high-pressure piping.
k Before installing the high-pressure pip-
ing, check it for the following defects.
If there is any of these defects, it can
c a u s e f u e l l e a k a g e . A c c o r d i n g l y,
replace the high-pressure piping.
q Check the taper seal of the connect-
ing part (Part (a): Part of 2 mm from
the end) for visible lengthwise slit (b)
and dent (c).
q Check part (d) (end of the taper seal:
Part at 2 mm from the end) for
your nail can feel.
3 Locknuts:
52.9 – 64.7 Nm {5.4 – 6.6 kgm}
a After having tightened the locknut, check
the valve clearance again.
7. Install cylinder head cover. (This is necessary

to prevent dust insertion into cylinders.
Remove the cylinder head cover later.)
24 PC2000-8
1) Install O-ring (83) on high-pressure pipe 6) Install the cylinder head cover.
sleeve (82). 3 Cylinder head cover mounting
2 O-ring: Engine oil (EO30) bolts:
2) Tighten sleeve nut (82) on fuel injector 14.7 – 34.3 Nm {1.5 – 3.5 kgm}
(75) temporarily. 7) Install rubber covers (54) and (55) on the
a If it is difficult to mount sleeve nut (82) sleeve nuts of high-pressure pipe (56).
onto the threads of mount, push the a Direct the slit section as follows dur-
end of sleeve nut (82) toward the ing installation.
injector using the rod. Then rotate the q Injector side (54): Downward
nut using a wrench. q Common rail system side (55):
3) Temporarily tighten sleeve nut (84) at the Toward the cylinder block
common rail section, too.
4) Tighten and secure injector holder (80)
permanently.
3 Injector holder mounting bolt (74):
58.9 – 73.5 Nm {6.0 – 7.5 kgm}
5) Tighten the sleeve nut with the specified
torque.
a Use a commercially available
(knuckle type) torque wrench to
tighten nuts with the correct torque.
3 Sleeve nuts on high-pressure pipe
(46) at injector side:
39.2 – 49 Nm {4 – 5 kgm}
3 Sleeve nuts on high-pressure pipe
(46) at common rail system side: 9. Install the high-pressure pipe clamp (between
39.2 – 49 Nm {4 – 5 kgm} the common rail system and fuel injector) in
a After having tightened the nuts, check the following procedure.
that O-rings (77) and (83) do not pro- 1) Manually tighten brackets (51-1) to (51-7)
trude from sleeve nut (82). and clamp (52) from the bottom of intake
manifold for temporary installation.
2) Also, manually tighten brackets (53-1) to
(53-3) and clamp from the top of intake
manifold for temporary installation.
3) Tighten the top and bottom clamps perma-
nently.
3 Top and bottom clamp bolts:
9.8 ± 1.0 Nm (1.0 ± 0.1 kgm}
4) Tighten brackets (51-1) to (51-7) and (53-
1) to (53-3) permanently.
5) Temporarily tighten clamp (50) and
bracket (49), and then tighten them per-
manently.
a Bracket (49): See the figure below.
3 Mounting bolts for bracket (49):
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
a Install the brackets and clamps simi-
larly in the left bank section.
PC2000-8 25
4) Tighten high-pressure pipe bracket (45)

permanently.
10. High-pressure pipe (between the common rail

system and fuel supply pump)
a For precaution for installation, refer to
"High-pressure pipe (between the com-
mon rail system and fuel supply pump)."
a Use a commercially available (knuckle
type) torque wrench to tighten nuts with
the correct torque.
1) Temporarily tighten high-pressure pipe
(48), and then tighten it permanently.
pipe: 39.2 – 49 Nm {4 – 5 kgm}
2) Manually tighten bracket (45) and clamps
(46) and (47) for temporary installation.
3) Tighten high-pressure pipe clamps (46)
and (47) permanently.
3 High-pressure pipe clamp bolts:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
26 PC2000-8
q Carry out the following installation in the [*5]

reverse order of removal. 3 Fuel tube joint bolts:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*1] 3 Fuel hose joint bolts:
3 Komaclone tube assembly hose clamps: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
[*6]
[*2] 3 Bracket assembly mounting bolts:
3 Air cleaner hose clamps: 49 – 68.6 Nm {5.0 – 7.0 kgm}
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*7]
[*3] Suction hose clamp 3 Air intake connector mounting bolts:
a Use new MIKALOR clamp. 49 – 68.6 Nm {5.0 – 7.0 kgm}
position). (Air hose insertion depth: Min. 80 k Make sure that a clearance of 10 mm mini-
mm) mum is provided between the high-pres-
2) Place the bridge (BR) under the clamping bolt sure piping and adjacent wiring harness. If
and adjust the overlapping (b) between the not, secure the clearance by adjusting the
bridge (BR) and band to 5 mm minimum. wiring harness position.
2 Threaded portion (BC) of clamping bolt: q Bleeding air
Lubricant (PANDO 18B from ThreeBond) Bleed air from the fuel system, referring to
a Never use an impact wrench. “Bleeding air from fuel system” in Testing and
a Displace the tightening positions of the adja- adjusting.
cent clamps by 180°.


the following.
BDG: 17 – 20 mm
[*4]
PC2000-8 27
Removal and installation of 7. Apply counter mark (E) on the damper and on
engine front seal 1
the front cover assembly.
a Be sure to apply the counter mark as the
Special tools pointer is shown on the damper.
New/Remodel
8. Lift and remove damper and clamp pulley
Sym-
Necessity
Part No. Part name assembly (7). [*2]
bol
Sketch
4 Damper and clamp pulley assembly (1):
Q'ty
75 kg
Seal puller assem-
3 790-331-1100 t 1
bly 9. Remove front seal (8) in the following proce-
795T-621-1430 Plate t 1 N Q dure.
A 795T-621-1440 Push tool t 1 N Q
4 01050-32240 • Bolt t 3
01050-32225 • Bolt t 3
01640-02232 • Washer t 3
Removal
battery.
1. Remove the radiator cooling assembly, refer-

ring to "Removal and installation of cooling 1) Replace the tip of tool A3 with the hook
assembly." type one.
2) Hitch the hook to the hoop of front seal
2. Loosen adjustment nut (2) of air conditioner (8).
compressor (1). 3) Remove front seal with impact of slide
a Repeat this step for both of air conditioner hammer (SH).
compressors.
q Tool A3
4. Loosen the mounting bolts of air conditioner

compressor bracket (4).
5. Remove air conditioner compressor belts (5).

[*1]
28 PC2000-8
a CS: Crankshaft Installation
1. Clean, degrease and then dry the contact sur-

face between the front cover and front seal.
2. Using a clean cloth, remove foreign matter

deposited the crankshaft flange.
a Clean foreign matter deposited on the seal
lip surface (surface around the crankshaft)
and then degrease and dry the surface.
a Check the crankshaft end face corner and
lip siding surface for scratches due to the
housing, burrs or rusts.
3. Install front oil seal (8) according to the follow-

ing procedure.
a Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and
rust of the housing.
a When installing the seal, do not apply oil
or grease to the shaft and seal lip. Wipe
off the oil from the shaft.
1) The surface having the parts number (PN)

marking must face to the outside of
engine.
2) Tighten bolts using the tool A4 (plate),

and press oil seal (8) to the shaft end.
PC2000-8 29
3) Using the A4 push tool, press oil seal (8) [*2]

in the front case until it becomes the Installation of damper and crankshaft pulley assem-
dimension (a) as shown in the figure. bly
a Oil seal press fit dimensions 1) Install the damper and crankshaft pulley
a: 17 mm (from shaft end surface) assembly by aligning it to the crankshaft
b: 25.1 mm (from front cover end sur- dowel pin.
face) 2) Tighten each mounting bolt 3 times in the
procedure shown in the figure.
2 Damper and crankshaft pulley
a s s e mb l y mo u n t i n g b o l ts a n d
washers: Engine oil (EO30)
3 Damper and crankshaft pulley
assembly mounting bolts
1st time: 73.5 ± 19.6 Nm {7.5 ± 2.0 kgm}
2nd time: 245 ± 19.6 Nm {25 ± 2.0 kgm}
3rd time: 744.8 ± 19.6 Nm {76 ± 2.0 kgm}
q Carry out the following installation in the

reverse order of removal.
[*1]
q Adjust the tension of the air conditioner com-
pressor belt tension, referring to "Adjusting air
conditioner compressor belt tension" in Testing
and adjusting.
a When the damper and crankshaft pul-

ley have been disassembled, reas-
semble them by tightening their
mounting bolts in the procedure
2 Damper mounting bolts and wash-
ers: Engine oil (EO30)
3 Damper mounting bolts:
98 – 122 Nm {10.0 – 12.5 kgm}
30 PC2000-8

engine rear seal 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
Seal puller assem-
3 790-331-1110 t 1
bly
A 795T-621-1540 Push tool t 1 N Q
5 01050-32060 • Bolt t 5
01640-02032 • Washer t 5 7. Remove rear seal (2).
a Take care in the removal not to damage
Removal the seal installation position on the fly-
k Lower the work equipment completely to wheel housing and the seal contact face
the ground and stop the engine. on the crankshaft.
k Loosen the hydraulic tank cap gradually to a Before removing, slightly drive the seal in
release the inside pressure of the hydraulic once to free it from fixation.
tank. a When rear seal (2) is fixed too hard to the
k Lock the work equipment lock lever. flywheel housing (FWH), remove the fol-
k Disconnect the negative terminal (–) of the lowing procedure.
battery. 1) Replace the tip of tool A3 with the drill
type one.
1. Drain the hydraulic oil. 2) Drill through a hole of approx. 3 mm
6 Hydraulic tank: 1,300 l dia. on rear seal (2).
3) Insert the top end of tool A3 into the
drilled hole, and remove the rear seal
2. Remove engine, PTO and hydraulic pump by the impact of slide hammer (SH).
assembly referring to "Removal and installa- (Apply the slide hammer evenly not to
tion of engine, PTO and hydraulic pump tilt the rear seal.)
assembly". a Remove the metal powders completely.
a When the sleeve is attached, cut sleeve
3. Remove PTO assembly referring to "Removal (5) using a gad and hammer to remove it.
and installation of PTO assembly". a Take care not to damage crankshaft (4).
4. Disconnect wiring harness (1-1) of rotation

sensor (1-2) from its connector.
5. Remove rotation sensor (1-2). [*1]
6. Flywheel assembly
1) Lift and hold flywheel assembly (1).
2) Remove the mounting bolts.
3) Using forcing screws [1], separate the fly-
wheel from the crankshaft.
4) Lift and remove flywheel assembly (1)
. [*2]
4 Flywheel assembly: 130 kg
PC2000-8 31
q Tool A3 Installation
1. Rear seal (2)

a Check the Teflon seal (Laydown lip seal)
by checking the wear of the shaft and
replace it with the “Standard seal” or
“Sleeved seal”.
a When wear on the shaft is not serious and
only makes it look lustrous (depth of wear
is 10 mm or less when checked with finger
cushion) and no scratch is recognized,
assemble the standard seal (A). When the
above is not applicable, assemble sleeved
seal (B).
a (5): Shows the sleeve.
a Handle rear seal (2) and sleeve (5) as an
integral part. Don't try to separate them.
a Clean, degrease and then dry the contact

surface between the flywheel housing and
rear seal.
a Clean foreign matter deposited on the seal
lip surface (surface around the crankshaft)
and then degrease and dry the surface.
a Check the crankshaft end face corner and
lip siding surface for scratches due to the
housing, burrs or rusts.
32 PC2000-8
2. Installation procedure of standard seal 3. Installation procedure of seal having sleeve

a Do not apply any grease, oil and others to a Do not apply any grease, oil and others to
the seal lip surface. the seal lip surface.
1) Apply rear seal (2) on the end of crank- 1) Apply sleeve (5) of rear seal (2) on the
shaft (4). end of crankshaft (4).
a Install the rear seal in the correct a Install the rear seal in the correct
direction. direction.
2) Manually push the metal ring of rear seal 2) Manually push the sleeve (5) of rear seal
(2) evenly, and insert in its position. (2) evenly, and insert in its position.
3) Using the tool A5, further press and insert 3) Using the tool A5, further press and insert
rear seal (2) evenly. rear seal (2) evenly.
4) Using the tool A5, press rear seal (2) by 4) Using the tool A5, press rear seal (2) by
tightening bolts equally. tightening bolts equally.
a Press rear seal (2) until tool A5 a Tool A5 presses both the metal ring
reaches crankshaft (4). and sleeve (5) of rear seal (2) simulta-
q Press fit method of oil seal (from neously.
flywheel housing end surface) a Press rear seal (2) until tool A5
a: 13.5 mm reaches crankshaft (4).
q Press fit method of oil seal (from q Press fit method of oil seal (from
crankshaft end surface) flywheel housing end surface)
b: 25.7 mm a: 13.5 mm
a After having pressed the rear seal, q Press fit method of oil seal (from
remove the red sealant form outer crankshaft end surface)
edge. b: 25.7 mm
a After having pressed the rear seal,
remove the red sealant form outer
edge.
PC2000-8 33
q Carry out the following installation in the 5) After having installed the flywheel assem-
reverse order of removal. bly, check for its facial runout and radial
runout using dial gauge [2].
[*1] Standard value for facial runout:
Engine speed sensor Max. 0.25 mm
a Tighten the mounting bolt until the sensor end Standard value for radial runout:
contacts the ring gear teeth of flywheel. Then, Max. 0.25 mm
return the bolt for 3/4 to 1 turn, and tighten the
locknut.
3 Engine speed sensor locknut:
49.0 – 68.6 Nm {5 – 7 kgm}
[*2]
Flywheel assembly
a Install the flywheel assembly by aligning it to
the crankshaft dowel pin.
a After having tightened the mounting bolts,
mount plate [1] between the flywheel and the
flywheel housing so that the crankshaft does
not rotate.

a Tighten the mounting bolts in the procedure

2 Flywheel assembly mounting bolts:
Engine oil (EO30)
3 Flywheel assembly mounting bolts
1st time: 98 ± 19.6 Nm {10 ± 2 kgm}
2nd time: 294 ± 19.6 Nm {30 ± 2 kgm}
3rd time: 539 ± 19.6 Nm {55 ± 2 kgm}
34 PC2000-8
SEN02135-00
© 2006 KOMATSU
All Rights Reserved
36
SEN02136-00
PC2000-8

PC2000-8 20001 and up
Power train
Power train...................................................................................................................................................... 2
Removal and installation of PTO assembly.......................................................................................... 2
Disassembly and assembly of PTO assembly ..................................................................................... 3
Removal and installation of swing motor and swing machinery assembly........................................... 7
Disassembly and assembly of swing machinery assembly.................................................................. 9
Removal and installation of swing circle assembly ............................................................................ 19
Removal and installation of final drive assembly ............................................................................... 20
Disassembly and assembly of final drive assembly ........................................................................... 22
PC2000-8 1
Power train 1
Removal and installation of PTO 7. Lift PTO assembly (1) temporarily.

assembly 1
8. Remove 32 mounting bolts (2). [*1]
Removal
1. Remove engine, PTO and hydraulic pump 9. Lift and remove PTO assembly (1).
assembly, referring to "Removal and installa-
4 PTO assembly: 1,100 kg
tion of engine, PTO and hydraulic pump
assembly."
2. Remove hydraulic pump assembly, referring to

"Removal and installation of hydraulic pump
assembly."
3. Drain oil in the PTO case (lubricating oil).

6 Amount of lubricating oil: 36 l
4. Disconnect connector (11).
6. Disconnect hose (13). 10. Lift and remove output shaft (3).
11. Remove coupling (4). [*2]
12. Remove plate (5). [*3]
Installation
removal.
[*1]
3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
[*2], [*3]
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
2 PC2000-8
Disassembly and assembly of a The gear and bearing assemblies (5) and
PTO assembly 1
(15) may be either remain on the case
side or removed with the covers. In the lat-
1. Remove engine output shaft (1) if it is installed ter case, take care not to let the gear and
to the PTO assembly (2) side instead of the bearing assembly (15) drops during
engine side. removal.
2. Lay down PTO assembly (2) on the block [1]

with the pump side up.
4 PTO assembly: 1,100 kg
3. Using forcing screws, lift and remove cage

assemblies (3) and (4).
4. Using bar [2], lift and remove gear and bearing

assembly (5).
5. Using forcing screws [3], lift and remove cage

assembly (6).
PC2000-8 3
6. Turn over PTO case assembly (7). 10. Using puller [4], remove gear and bearing
assembly (11) from the cage assembly (8).
11. Remove snap ring (12) from the gear and

bearing assembly (11), and then remove bear-
ing inner race (13).
7. Remove mounting bolts of the cage assembly

(8). Using forcing screws on (B), remove cage
assembly.
12. Using puller [4], remove gear and bearing

assembly (14) from the cage assembly (6).
Remove gear and bearing assembly (15) from
the cage assembly (4) in the same manner.
8. Lift and remove cage assembly (8).
9. Remove snap ring (9) and remove bearing

(10).
4 PC2000-8
13. Using puller [5], remove bearings (16) from Assembly

gear and bearing assemblies (5), (14) and (15) 1. Using push tool [6], press bearing assemblies
respectively. (16) on both sides of the gears (5), (14) and
a Bearings are installed in both sides of the (15) respectively.
gear.
2. Press bearing assembly (17) to the gear (11) in
14. Remove bearing assembly (17) from the gear the same manner.
and bearing assembly (11) in the same man-
ner.
3. Install bearing inner race (13) and snap ring

(12) to the gear and bearing assembly (11).
4. Install gear and bearing assembly (11) to the

cage (8).
a Insert push tool [7] to the hole (A), and fit
bearing outer races by tapping in.
PC2000-8 5
5. Install gear and bearing assembly (14) to the 9. Turn over PTO assembly (7).
cage (6).
a Insert push tool [8] to the hole (AA), and fit
bearing outer races by tapping in.
10. Install cage assembly (6) using guide bolt [9].
6. Install gear and bearing assembly (5) to the

cage (3).
a Insert push tool [8] to the hole (AAA), and
fit bearing outer races by tapping in.
7. Fit gear and bearing assembly (15) by tapping

in to the cage (4) in the same manner.
11. Install cage assemblies (3) and (4) using guide

bolt [9].
8. Install cage assembly (8).

2 Mounting bolt: Liquid adhesive (LT-2)
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
6 PC2000-8
Removal and installation of swing 6. Lift and remove swing motor and swing
motor and swing machinery machinery assembly (8).
a When removing the assembly, take care
assembly 1
that they will not interfere with adjacent
Removal hoses.
k
4
Lower the work equipment completely to
Swing motor and swing machinery
the ground.
k
assembly: 1,200 kg
Release remaining pressure in hydraulic
circuit, referring to "Releasing remaining
pressure in hydraulic circuit" in Testing and
adjusting.
k Set steering lock lever to lock position.
a Two swing motor and swing machinery assem-

blies are used (front and rear).
Front side
1. Remove 6 work equipment hoses (1).
Rear side
7. Disconnect connector BV1 (9) (mating part:
V19).

a Fasten tags to hoses to identify them for
reinstallation.
9. Remove filter and bracket assembly (11).
2. Disconnect hoses (2) to (4). 10. Disconnect hose (12).

a Fasten tags to hoses to identify them for a SM: Swing motor and swing machinery
reinstallation. assembly - behind
3. Disconnect drain hose (5) from the bracket.
4. Remove step (6).
q For further removal steps, refer to Step 2

to 6 in the front side.
PC2000-8 7
Installation
removal.
[*1]
3 Mounting bolt:
1,520 – 1,910 Nm {155 – 195 kgm}

q Bleeding air
Bleed air referring to the section Testing and
adjusting, "Bleeding air from each part".
8 PC2000-8
Disassembly and assembly of 3. Cover

swing machinery assembly 1
Lift cover (4) and remove it using forcing
screws [1].
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
790-101-5621 Plate t 1
1 790-101-5641 Grip t 1
F
01010-51240 Bolt t 1
2 796T-626-1120 Push tool t 1 Q
Disassembly
1. Remove swing motor assembly (100) from
swing machinery assembly (101). 4. No. 1 sun gear
4
1) Remove thrust washer (5).
Swing motor assembly: 210 kg
2) Remove No. 1 sun gear (6).
2. Oil filler port 5. No. 1 carrier assembly

Remove bracket (1), and then remove oil filler 1) Pass wires over the carrier case, and then
port (2) and breather tube (3). lift and remove carrier assembly (7).
a Breather tube is provided only for front
machinery.
PC2000-8 9
2) Disassemble No. 1 carrier assembly by 7. No. 2 sun gear

the following procedure. 1) Remove No. 2 sun gear (15).
1] Drive pin (8) into the shaft (9).
2] Drive out shaft (9) upward to remove
it.
3] Pull out pin (8) from the shaft (9).
2) Remove thrust washer (16), ball (17) and

holder (18) from the No. 2 sun gear (15).
4] Pull out gear (10) from the carrier

(11), and remove thrust washer (12)
and bearing (13).
8. No. 2 carrier assembly

1) Pass wires over the carrier case, and then
lift and remove carrier assembly (19).
6. No. 1 ring gear

Remove No. 1 ring gear (14).
10 PC2000-8
2) Disassemble No. 2 carrier assembly by 9. Cover

the following steps. Remove 28 bolts (102), and then lift and
1] Drive pin (20) into the shaft (21). remove cover (27).
2] Drive out shaft (21) downward to
remove it.
3] Pull out pin (20) from the shaft (21).
10. No. 2 ring gear

Remove No. 2 ring gear (28).
4] Pull out gear (22) from the carrier

(23), and remove thrust washer (24)
and bearing (25).
11. Hub
1) Remove bolt (29).
2) Remove plate (30).
3) Remove hub (31).
5] Remove thrust washer (26).
PC2000-8 11
12. Pinion shaft assembly 5) Place the bolt hole of the cover assembly
When pulling out from the outer race side, (32) to the block [3] and set it on the press.
observe the following procedure. a Adjust the block height so that the
1) Remove mounting bolts of the cover pinion-to-press clearance is approx.
assembly (32). 150 mm.
6) Drive out the bearing (35) by pressing pin-
ion shaft (34).
a Press the pinion shaft straight to pre-
vent the shaft from tilting.
7) Remove cover assembly (32) from the
pinion shaft (34).
2) Apply case body (33) to the block [2] and

set it on the press.
a Adjust the block height so that the
pinion-to-press clearance is approx.
150 mm.
3) Drive out pinion shaft (34) by pressing it
down. 8) Remove oil seal (39) from the cover (38).
a The outer race comes off from the
lower bearing (35) and the inner race
comes off from the upper bearing
(36).
a Since the spherical bearing is used
here, do not hold the press down con-
stantly but release it occasionally.
4) Remove spacer (37).
13. Bearing
1) Remove bearing (36) from the case body
(33).
12 PC2000-8
2) When pulling out from the inner race side, Assembly

observe the following procedure. a Before assembly, clean the parts, check for
1] Apply cover assembly (32) to the dust or defect, and apply engine oil on the slid-
block [4] and set it on the press. ing parts.
a Adjust the block height so that a Do not reuse the bearing because the track
the pinion-to-press clearance is surface of the bearing can be damaged when
approx. 150 mm. excessive thrust load is applied during disas-
2] Drive out pinion shaft (34) by pressing sembly.
it down. a Do not reuse the oil seal, too. It can be
a The inner races come off from deformed during disassembly.
both the bearings (35) and (36).
3] Remove spacer (37). 1. Bearing
1) Perform expansion fit or use the press for
bearing (35) to install the case body (33).
4] Remove cover assembly (32).

5] Remove bearings (35) and (36) from
the case body (33). 2) Using tool F1, press oil seal (39) to the
cover (38).
2 Oil seal outside perimeter:
Gasket sealant (LG-6)
2 Oil seal lip: Grease (G2-LI)
PC2000-8 13
3) Install cover assembly (32) by aligning its 3. Wheel hub

oil groove with the drill hole (drain port) of 1) Using tool F2, press bearing (36). Dimen-
the case body (33). sion (b) shall be 1 to 2 mm.
a Be careful not to let the gasket seal- a Press bearing by pressing both the
ant run over the drain port when inner and outer races simultaneously.
applying it. Do not press the inner race only.
2 Cover mounting face: a After press fitting, check that the case
Gasket sealant (LG-6) rotates smoothly.
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
4. Hub
1) Install hub (31).
2. Pinion shaft assembly 2) Install plate (30).
1) Place spacer (37) on the push tool [5], and 3) Tighten bolt (29).
set case body (33). 2 Mounting bolt:
a Adjust the case-to-press clearance Liquid adhesive (LT-2)
(a) for 1 to 2 mm. 3 Mounting bolt:
2) Make sure the spacer (37) is correctly 343 – 427 Nm {35 – 43.5 kgm}
positioned. Set pinion shaft (34) and press
bearing (35) using the press.
a Make sure that the seal lip contact
surface of the shaft comes to the cen-
ter to prevent it from tilting.

1) Assemble No. 2 carrier assembly by the
following steps.
1] Install thrust washer (26).
14 PC2000-8
However the thinner areas vary

depending on individual carrier.
Always check the area before
installation.
a Caulk the pin area (arrow mark)
of the carrier after having
installed the pin.
a After having assembled the car-
rier assembly, check that the
gear (22) rotates smoothly.
a The trace of caulking is left on

the end surface of the side hole
(h) when the pin was installed
previously. Correct the shape
(protrusion) of the inner diame-
ter before installation.
2] Assemble bearing (25) on the gear
(22), attach thrust washers (24) on
both sides, and place gear assembly
to the carrier (23).
3] Align the pin holes of the shaft (21) to 2) Pass wires over the carrier case, and then
that of carrier (23), and then drive in lift and install the carrier assembly (19) by
the shaft by lightly tapping with a plas- aligning with the gear of the hub.
tic hammer.
a Install shaft as rotating the plane-
tary gear. Use care not to dam-
age the thrust washers.
4] Insert pin (20).
a Check the pin for deformation on
the pin groove or protrusion, and
replace if defective.
a Do not locate the pin at the same
position where it was caulked
previously.
a When installing the pin, be care-
ful that the claws (b) at 3 loca-
tions on the circumference do not
overlap with the areas (c) where
the carrier is thinner than other
areas.
PC2000-8 15
6. No. 2 ring gear 2) Install No. 2 sun gear (15).

Install No. 2 ring gear (28).
2 Mounting face with case:

Assemble No. 1 carrier assembly in the follow-
ing procedure.
7. Cover a The trace of caulking is left on the end sur-
1) Install cover (27) by aligning the oil groove face of the side hole (h) when the pin was
of the oil filler port with the protrusion of installed previously. Correct the shape
the case body. (protrusion) of the inner diameter before
2 Mounting face with No. 2 ring gear: installation.
Gasket sealant (LG-6) 1) Assemble bearing (13) on the gear (10),
2) Tighten 28 bolts (102). attach thrust washers (12) on both sides,
and place gear assembly to the carrier
(11).
8. No. 2 sun gear

1) Install thrust washer (16), ball (17) and
holder (18) to the No. 2 sun gear (15). 2) Align the pin holes of the shaft (9) to that
of carrier (11), and then drive in the shaft
by lightly tapping with a plastic hammer.
a Install shaft as rotating the planetary
gear. Use care not to damage the
thrust washers.
3) Insert pin (8).
a Check the pin for deformation on the
pin groove or protrusion, and replace
if defective.
a Do not locate the pin at the same
position where it was caulked previ-
ously.
a Caulk the pin area (arrow mark) of the
carrier after having installed the pin.
[Refer to section 5., 1), 4].]
16 PC2000-8
a After having assembled the carrier 11. No. 1 sun gear

assembly, check that the gear (10) 1) Install thrust washer (5).
rotates smoothly. 2) Install No. 1 sun gear (6).
4) Pass wires over the carrier case, and then 12. Cover
lift and install the carrier assembly (7) by Lift and install cover (4) by aligning the oil filler
aligning with the No. 2 sun gear (15). port.
2 Cover mounting face:
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
10. No. 1 ring gear

1) Install No. 1 ring gear (14) by aligning the
drill hole of the oil filler port.
2 Mounting face:
PC2000-8 17
13. Oil filler port

Install bracket (1), and then install oil filler port
(2) and breather tube (3).
2 Oil filler port mounting part:
3 Oil filler port:
42.1 – 70.6 Nm {4.3 – 7.2 kgm}
3 Mounting bolt:
98 – 123 Nm {105 – 12.5 kgm}
14. Install swing motor assembly (100) to swing

machinery assembly (101).
18 PC2000-8
Removal and installation of swing Installation

circle assembly 1
removal.
Removal
1. Remove revolving frame assembly, referring to [*1]
"Removal and installation of revolving frame 2 Threaded portion of swing circle mounting
assembly." bolt: Liquid adhesive (LT-2)
3 Swing circle mounting bolt:
2. Remove 38 mounting bolts (1). [*1] 2,746 ± 294 Nm {280 ± 30 kgm}
3. Install 3 eyebolts (M36) on top of the swing cir- [*2]

cle. 2 Swing circle mounting face:
4. Lift and remove swing circle assembly (2). [*2] 2 Amount of grease in oil bath:
4 Swing circle assembly: 3,330 kg Grease (G2-LI) Approx. 80 l

a Note that the capacity up to the top of the inter-
nal gear is 500 l.
a Apply grease to the internal gear.

2 Internal gear: Grease (G2-LI)
a Fill grease to the seal groove.

2 Seal groove: Grease (G2-LI)
a When install the assembly, align the inner race
soft zone (a) (S-mark) and the outer race soft
zone (b) (S-mark) to the positions as shown in
the figure below. (Arrow mark points to the
front of the machine.)
PC2000-8 19
Removal and installation of final 4. Temporarily lift final drive assembly (2).
drive assembly 1
5. Remove 23 mounting bolts and then lift and
Removal remove final drive assembly (2). [*2]
1. Spread the track shoe assembly, referring to a Take care not to damage the nipple seal
"Removal of track shoe assembly." face of the hose installing portion.
2 Final drive assembly: 2,830 kg
the ground and stop the engine. Then,
gradually loosen the oil filler cap of the
hydraulic tank to release the pressure
inside the hydraulic tank.
2. Remove travel motor assembly, referring to

"Removal of travel motor assembly."
3. Remove sprocket assembly (1) from the final

drive assembly (2). [*1]
2 Sprocket assembly: 260 kg
a If it is difficult to remove the sprocket (1),

burrs (B) may have been formed. In this
case, remove the burrs (B) with a grinder
before removing the sprocket (1). (Do this
only when burrs are found.)
20 PC2000-8
Installation
removal.
[*1]
3 Mounting bolt:
2,110 – 2,450 Nm {215 – 250 kgm}
[*2]
3 Mounting bolt:
1,960 – 2,450 Nm {200 – 250 kgm}
q Add oil
Add power train oil (TO30) up to the specified
level from the oil filler port. Run the engine and
travel for a while. Then check the oil level
again.
q Bleeding air
Bleed air from the travel motor, referring to
"Bleeding air from each part" in Testing and
adjusting.
PC2000-8 21
Disassembly and assembly of 2. Case and gear assembly

final drive assembly 1
1) Using eyebolt, lift and remove case and
gear assembly (5).
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
J 791-585-1510 Installer t 1
Disassembly
1. Case assembly
1) Using eyebolt (M16 mm, P = 2.0), lift and
remove case assembly (1).
2) Disassemble case and gear assembly in

the following procedure.
1] Remove bolt (6) and holder (7), and
then remove shaft (8) and spacer (9).
2) Remove bearing outer races (3) and (4)

from the case (2).
2] Remove gears (10) and (11).

a To avoid the bearing (12) inter-
fere with the gear (10), pull up
both gears simultaneously.
22 PC2000-8
3] Remove 2 bearing inner races (13) 7] Remove thrust washer (18) from the
from the gear (10). case (14).
8] Remove oil lubrication plate (18-1).
4] Remove 2 bearing inner races (12)

from the gear (11). 3. Carrier assembly (small)
1) Using eyebolt, lift and remove carrier
assembly (19).
5] Remove bearing outer races (15) and

(16) from the case (14).
6] Remove oil lubrication tube (17). 2) Disassemble carrier assembly in the fol-
lowing procedure.
1] Remove lockplate (20).
PC2000-8 23
2] Using the press to push out shaft 2) Using eyebolt (24 mm, P=3.0), screw in
(21). forcing screws, and then lift and remove
3] Remove gear (22) and bearing (23). carrier assembly (29).
a The outer race is coupled with
the bearing. Apply counter marks
on them.
4] Remove spacers (24) and (25) from
the gear (22), and then remove snap
ring (26).
3) Disassemble carrier assembly in the fol-

lowing procedure.
1] Remove lockplate (30).
4. Ring gear (small)

Lift and remove ring gear (27).
2] Using the press to pull out shaft (31).

3] Remove 2 thrust washers (32).
4] Remove gear (33) and remove bear-
ing (34) and spacer (35).
5. Carrier assembly (large)

1) Reverse final drive assembly (28).
24 PC2000-8
5] Remove button (37) from the carrier 2) Remove shim (40).

case (36). Check the thickness and quantity of the
shims in advance.
6. Shaft
Lift and remove shaft (38). 3) Lift and remove ring gear assembly (41).
7. Ring gear assembly (large) 4) Remove 6 lockplates (42), and then

1) Remove retainer (39). remove case (44) from the ring gear (43).
a Apply counter marks on them before
removal.
PC2000-8 25
8. Case assembly 4) Remove floating seal (49) and 2 bearing

1) Using the press, remove case assembly outer races (50) from the case (48).
(45) from the housing assembly (46).
9. Housing assembly
2) Lift and remove case assembly (45). 1) Remove floating seal (49) and 2 bearing
inner races (47) from the housing (51).
3) Remove bearing inner race (47).

2) Remove spacer (52) from the housing
(51).
26 PC2000-8
Assembly 2. Case assembly

a Before assembly, clean the parts and check for 1) Assemble following parts to the case (48).
dust or defect. 1] Perform expansion fit to install 2 bear-
a Apply engine oil on the sliding parts and ing outer races (50).
assemble them. 2] Using tool J1, install floating seal
a Using engine oil, remove dust completely from (49).
the O-ring surface of the floating seal. a Thoroughly degrease the floating
seal and O-ring contact surface
k Be careful not to apply impact or drop the of the housing.
parts during installation. Even the slightest a Use tool J1 and apply force
damage on the floating seal can cause oil evenly on the O-ring of the float-
leaks. ing seal for tightening so as not
to let it twist.
1. Housing assembly
Assemble following parts to the housing (51).
1) Install spacer (52).
2) Lift and install case assembly (45) by

aligning the seal.
2) Perform shrink fit, install bearing inner

race (47).
3) Using tool J1, install floating seal (49).
a Thoroughly degrease the floating seal
and O-ring contact surface of the
housing.
a Use tool J1 and apply force evenly on
the O-ring of the floating seal for tight-
ening so as not to let it twist.
PC2000-8 27
3. Bearing 5. Preload adjustment and retainer

Install bearing inner race (47). Adjust the preload in the following procedure.
1) Install retainer (39) by tightening with 4
mounting bolts evenly.
2) Remove 4 mounting bolts and rotate the
case (48). Then check that it rotates
smoothly together with the bearing.
4. Ring gear
1) Install ring gear (43) to the case (44) and
fix with 6 lockplates (42).
a Install by aligning the counter marks.
3 Mounting bolt:
98.5 – 123 Nm {10 – 12.5 kgm} 3) Tighten with 4 mounting bolts evenly
2 Mounting bolt: Adhesive (LT-2) again.
3 Mounting bolt: 34.3 Nm {3.5 kgm}
4) Measure the retainer-to-housing clear-
ance (a) either by using a depth microme-
ter [1] through the mounting bolt hole, or
by using a clearance gauge from inside of
the case.
2) Lift and install ring gear assembly (41) to

case (48).
28 PC2000-8
5) Select shim(s) (40) so that its thickness 6. Shaft

equals the measured value plus 0 to 0.1 1) Lift and install shaft (38).
mm, and install.
7. Carrier assembly (large)

6) Install retainer (39). 1) Disassemble carrier assembly (29) in the
3 Mounting bolt: following procedure.
824 – 1,030 Nm {84 – 105 kgm} 1] Install button (37) to the carrier case
2 Mounting bolt: Adhesive (LT-2) (36).
7) Set dial gauge [2] on the ring gear (43),

pry out the case (48) and measure the end
play.
a End play: 0 – 0.1 mm
a If the end play does not meet the
standard value, add or remove the
number of shim, and repeat Step 5)
and 6).
PC2000-8 29
2] Assemble bearing (34) and spacer 2) Apply gasket sealant to the mounting face
(35) to the gear (33). of the case assembly of the carrier, and
a The bearing is coupled with the then install the carrier assembly (29) by
spacer. Always reassemble with aligning with the shaft.
original pairs. 2 Mounting face of carrier:
3] Apply thrust washers (32) on both Gasket sealant (LG-6)
side of the gear (33), and install them 3 Mounting bolt:
to the carrier. 1,520 – 1,910 Nm {155 – 195 kgm}
a Align the inner diameter of the 2 Mounting bolt: Adhesive (LT-2)
spacer to that of the bearing.
4] Perform expansion fit to Install shaft
(31).
a If it is difficult to install the shaft,
press it using the press.
8. Carrier assembly (small)

1) Assemble carrier assembly (19) in the fol-
lowing procedure.
1] Install snap ring (26) to the gear (22).
2] Install spacer (24), and then install
5] Install lockplate (30). outer race of the bearing (23).
a Install lockplate (30) to the shaft, a The outer race is coupled with
and use guide bolt to match the the bearing. Always check the
bolt hole. counter marks for reassembly.
3 Mounting bolt: 3] Assemble inner race of the bearing
245 – 309 Nm {25 – 31.5 kgm} (23) and spacer (25) to the gear, and
2 Mounting bolt: Adhesive (LT-2) set them to the carrier.
a Align the inner diameter of the
spacer (25) to that of the bearing.
4] Perform expansion fit to install shaft
(21).
a If it is difficult to install the shaft,
press it using the press.
30 PC2000-8
5] Install lockplate (20). 9. Ring gear assembly (small)

a Install lockplate (20) to the shaft, Apply gasket sealant to the ring gear (27), and
and use guide bolt to match the lift and install it.
bolt hole. 2 Mounting face: Gasket sealant (LG-6)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
2 Mounting bolt: Adhesive (LT-2)
10. Case and gear assembly

1) Assemble case and gear assembly in the
following procedure.
2) Lift and install carrier assembly (19) by 1] Install bearing inner race (12) to the
aligning the shaft. gear (11).
PC2000-8 31
2] Install oil lubrication plate (18-1) to 4] Tighten oil lubrication tube (17).
the case (14). 3 Mounting bolt:
a Note the assembly direction 58.8 – 73.5 Nm {6 – 7.5 kgm}
(right to left or up and down). 2 Mounting bolt: Adhesive (LT-2)
DH: Drain hole 5] Install bearing outer races (15) and
2 Mating face: (16) to the case (14).
a Thoroughly remove excessive
gasket that runs into the hole.
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
6] Install 2 bearing inner races (13) to

the gear (10).
7] Install gears (10) and (11).

a To avoid the bearing (12) inter-
fere with the gear (10), pull up
both gears simultaneously.
3] Install thrust washer (18) by aligning
with the dowel pin.
32 PC2000-8
8] Install spacer (9) to the shaft (8). 2) Apply gasket sealant to the mounting face,
9] Install shaft (8) to the gear, install and then lift and install case assembly (1).
holder (7) and tighten with bolt (6). 2 Mounting face:
3 Mounting bolt: Gasket sealant (LG-6)
245 – 309 Nm {25 – 31.5 kgm}
2) Apply gasket sealant to the mounting face,

and then lift and install case and gear
assembly (5).
2 Mounting face:
11. Case assembly

1) Install bearing outer races (3) and (4) to
the case (2).
PC2000-8 33
SEN02136-00
© 2006 KOMATSU
All Rights Reserved
34
SEN02137-00
PC2000-8

PC2000-8 20001 and up
Undercarriage and frame

Undercarriage and frame ................................................................................................................................ 2
Removal and installation of track shoe assembly ................................................................................ 2
Removal and installation of idler assembly .......................................................................................... 4
Disassembly and assembly of idler assembly...................................................................................... 5
Disassembly and assembly of idler adjust cylinder assembly.............................................................. 7
Removal and installation of idler cushion cylinder assembly ............................................................... 8
Disassembly and assembly of idler cushion cylinder assembly........................................................... 9
Removal and installation of track roller assembly .............................................................................. 10
Disassembly and assembly of track roller assembly...........................................................................11
Removal and installation of carrier roller assembly............................................................................ 13
Disassembly and assembly of carrier roller assembly ....................................................................... 14
Removal and installation of revolving frame assembly ...................................................................... 18
Removal and installation of counterweight assembly ........................................................................ 21
PC2000-8 1
Undercarriage and frame 1
Removal and installation of track

shoe assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
790-434-1502 Remover & installer t 1
Cylinder
R 1 790-101-4300 t 1
(1,471 kN {150 ton})
790-101-1102 Hydraulic pump t 1
4. Apply a block or jack [1] (10-ton) to under the
Removal shoe (3) on the idler side and pull out the guide
1. Master pin positioning pin [2]. [*2]
a Move the master pin to the middle of the
front idler and carrier roller. As the track
shoe is extended backward, retain the
space for it.
2. Loosen the track shoe tension. [*1]

k When loosening lubricator (1), don't
turn it more than 360°.
a If the track shoe tension does not slacken
after loosening the lubricator, move the
machine body forward/reverse.
5. Lift the end of the track shoe with a crane.

Slowly move the machine backward and
extend the track shoe assembly (3).
3. Remove the snap ring and pull out the master

pin using tool R1.
2 PC2000-8
Installation
removal.
[*1]
a Before pressing grease, check the thrusting
dimension (A) of the plunger (P) of hydraulic
cushion cylinder (S).
Thrusting dimension (A): 135 ± 5 mm
k Always adjust the thrusting dimension (A)
of the plunger (P) of the hydraulic cushion
cylinder (S) to a specified value, or a major
accident may occur when adjusting the
track shoe tension.
a For the tension of track shoe assembly, refer to

the "Adjusting track shoe tension" in Testing
and adjusting.
3 Lubricator: 74.5 – 88 Nm {7.6 – 9 kgm}
2 Grease (G2-LI):
4,600 ml (standard position)
[*2]
a Install spacer (4) and washer (5) to the link,
joint it to the lower link and install the guide pin.
PC2000-8 3
Removal and installation of idler Installation

assembly 1
removal.
Removal
k Lower the work equipment completely to [*1]
the ground and stop the engine. 3 Mounting bolt (4):
k Loosen the cap of the hydraulic tank gradu- 1,720 ± 196 Nm {175 ± 20 kgm}
ally to release the pressure inside the
hydraulic tank. [*2]
k Set the work equipment lock lever to the 3 Idler adjust cylinder assembly mounting bolt:
lock position. 927 ± 98 Nm {94.5 ± 10 kgm}
k Release residual pressure in the circuit,
referring to the "Releasing residual pres-
sure in HIC circuit" in Testing and adjust-
ing.
1. Remove the track shoe assembly, referring to

"Removal and installation of track shoe assem-
bly."
2. Lift and remove idler adjust cylinder assembly

(2). [*1]
a Lift the assembly horizontally using the
lever block on the adjust cylinder side.
a Pull out and remove idler adjust cylinder
assembly (2).
4 Idler adjust cylinder assembly: 1,700 kg
3. Remove mounting bolt (4) and remove the

yoke (3). [*2]
4 Yoke (3): 460 kg
4 PC2000-8
Disassembly and assembly of 6. Set idler to block [1].

idler assembly 1
7. Pull out shaft (4) from the idler.
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
L 3 791-542-1520 Installer t 1
Disassembly
1. Remove plug (1) and drain oil.
6 Idler assembly: 1.4 l
2. Pull out mounting bolt (3) of support (2) and

remove the support. 8. Remove bushings (10) and (11) from the idler.
3. Remove O-ring (5) from shaft (4).
4. Remove spacer (6) and remove dowel pin (7).
5. Remove floating seal assembly (9) from sup-

port and idler (8).
PC2000-8 5
Assembly q Refilling with oil

1. Press bushings (2) and (3) to the idler (1). a Add engine oil to the specified amount
from the oil filler port.
5 Amount of oil: 1.4 l (GO140)
2. Using tool L3 (see the tool table), install float-

ing seal (4) to the idler.

ing seal (5) to the support.
q Carry out the installation of the shaft,
spacer and support in the reverse order of
removal.
6 PC2000-8
Disassembly and assembly of 5. Remove dust seal (10) from yoke (5).
idler adjust cylinder assembly 1
Disassembly
1. Remove guard (1), plates (2) and (3) from the
idler assembly.
2. Remove cylinder assembly (4) from the idler

assembly.
Assembly
a Refer to a figure included in the Disassembly
section.
1. Install wear ring (9) and packing (8), and then
install snap ring (7) to plunger (6).
2. Fill the inside of plunger (6) with grease (G2-

LI).
3. Remove plunger assembly (6) from yoke (5). a Standard capacity: 4,600 cc
k Remove the lubricator and inject the air a Always apply grease to the plunger in
to push out the plunger. Care must be advance because the air cannot com-
paid for jumping plunger. pletely purged once plunger (6) is installed
to yoke (5).
3. Apply grease, lift and lower yoke (5) on the

side of plunger (6) and install.
4. Install dust seal (10) to yoke (5).
4. Remove snap ring (7), and then remove pack-

ing (8) and wear ring (9) from the plunger (6).
PC2000-8 7
Removal and installation of idler 4. Remove air bleeding bolt (3).

cushion cylinder assembly 1
Removal a (6): Idler adjust cylinder assembly mount-
k Lower the work equipment completely to ing bolt
k Loosen the cap of the hydraulic tank gradu-
hydraulic tank.
lock position.
k Release residual pressure in the circuit,
referring to "Releasing residual pressure in
HIC circuit" in Testing and adjusting.
1. Remove the track shoe assembly, referring to

"Removal and installation of track shoe assem-
bly."
2. Remove step (1). 6. Temporarily lift the idler cushion cylinder

assembly (5).
7. Remove mounting bolts (6), and then lift and

remove idler cushion cylinder assembly (5).
4 Idler cushion cylinder assembly: 480 kg
3. Lift and remove idler adjust cylinder assembly

(2).
a Pull out and remove idler adjust cylinder
assembly (2).
4 Idler adjust cylinder assembly: 1,700 kg
Installation
removal.
q Bleeding air
a Bleed air from inside the idler cushion and
press-in pressurized oil, referring to "Bleeding
air from HIC circuit and pressing-in pressurized
oil" in Testing and adjusting.
8 PC2000-8
Disassembly and assembly of Assembly

idler cushion cylinder assembly 1
1. Install bushing (10) (outside diameter: 144
mm) to the cylinder.
Disassembly
1. Remove gland (1). 2. Press dust seal (9) (outside diameter: 160
mm) and Install snap ring (8).
2. Remove plunger assembly (2) from cylinder
(3).
a For the rest of procedures, refer to a figure in

the Disassembly section.
3. Remove snap ring (4), and then remove pack-
ing (5) and wear ring (6) from plunger (7). 3. Install wear ring (6) and packing (5) to plunger
(7), and then install snap ring (4).
4. Apply grease (G2-LI) and install plunger

assembly (2) to cylinder (3).
5. Install O-ring and install gland (1).

a If the end of the bolt protrudes from the
gland, grind it flush to the gland plane.
a Install the gland so that the tube mounting
hole will be parallel to the bracket mount-
ing plate of the cylinder.
4. Remove snap ring (8) from cylinder (3) and

remove dust seal (9).
5. Remove bushing (10).
PC2000-8 9
Removal and installation of track 4. Set tool L4, remove mounting bolt (3) and
roller assembly 1
remove track roller assembly (4). [*1]
Special tools 5. Using tool L4, remove track roller assembly (4)
by maintaining balance.
New/Remodel
4 Track roller assembly: 345 kg
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
790-401-1700 Lifting tool t 1
L 4
790-431-1021 Adapter t 1
Removal
hydraulic tank.
lock position.
1. Loosen the track shoe tension, referring to Installation

"Removal of track shoe assembly."
removal.
2. Remove track roller guards (1) and (2).
[*1]
3 Roller mounting bolt:
1,520 – 1,910 Nm {155 – 195 kgm}
3. Using the work equipment, push up the track

frame on the removal side.
k After lifting the machine, set the block
on the track shoe.
10 PC2000-8
Disassembly and assembly of 4. Pull out floating seals (7) and (8) from roller (5)
track roller assembly 1
and collar (3),
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
5 796-675-1510 Installer t 1
L
6 791-601-1000 Oil pump t 1
Disassembly
1. Remove plug (1) and drain oil.
6 Track roller assembly: 1.3 – 1.45 l
5. Remove bushings (9), (10) from roller (5).
2. Remove bolt (2), and remove collar (3).
3. Remove shaft (4) from roller (5), and remove

O-ring (6).
PC2000-8 11
Assembly
1. Press bushings (9) to track roller (5).
2. Reverse the roller and press bushings (10).
7. Apply the reference pressure to the roller oil

filling port and check the seal for the air leak-
age.
a Reference pressure: 0.1 MPa {1 kg/cm2}
ing seals (7) to track roller (5).

ing seals (8) to collar (3).
8. Using tool L6 (see the tool table), fill the track

roller assembly with oil.
5 Amount of oil: 1.3 – 1.45 l (GO140)
5. Install O-ring (6) to shaft (4) and assemble

shaft (4) to track roller (5).
6. Install collar (3) to shaft (4) and install bolt (2).

3 Bolt (2): 245 – 309 Nm {25 – 31.5 kgm}
a Track roller play in axial direction:
0.29 – 0.68 mm
a (1): Plug (Install after filling oil)
9. Install the plug (1) (stated in the preceding

paragraph).
12 PC2000-8
Removal and installation of 5. Remove bolt (3).

carrier roller assembly 1
6. Open bracket (4) using a driver, and remove
Removal the carrier roller from the bracket.
4 Carrier roller assembly: 175 kg
hydraulic tank.
lock position.
1. Loosen the track shoe tension slightly, refer-

ring to "Adjusting track shoe tension" in Testing
and adjusting.
2. Using a hydraulic jack [1], push up the track

shoe.
Installation
removal.
[*1]
3 Roller mounting bolt:
1,520 – 1,910 Nm {155 – 195 kgm}
4. Lift and remove carrier roller bracket assembly

(2).
a Pull the carrier roller assembly to outside
but within the safe range from falling.
4 Carrier roller bracket assembly: 130 kg
PC2000-8 13
Disassembly and assembly of Disassembly

carrier roller assembly 1
1. Remove plug (14) and drain oil from the carrier
roller assembly.
Special tools
6 Carrier roller assembly: 0.86 – 0.94 l
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
1 791-575-1520 Installer t 1
L
2 796T-930-1110 Push tool t 1 N Q
q Sectional view
a The numbers represent those in the texts.
2. Remove cover (10) from roller (1).

a O-ring (11) is installed to cover (10).
3. Remove dowel pin (12) and spacer (13).
4. Remove plate (9) from roller (1).
5. Remove shaft (7) from roller (1).
14 PC2000-8
6. Remove floating seal (5) from shaft (7).

a Take care so that the seal face will not be
damaged.
7. Remove ring (4) from shaft (7).
8. Remove floating seal (6) from roller (1).

a Take care so that the seal face will not be
damaged.
9. Using the push tool, remove bushings (2) and

(3) from roller (1).
q Press fitting force (Reference):
Bushing (2):
0.2 – 6.9 kN {200 – 6,900 kg}
Bushing (3):
1.6 – 11.3 kN {1,600 – 11,300kg}
PC2000-8 15
Assembly
1. Bushing
1) Using the push tool, press bushing (2) to
roller (1).
2) Reverse the roller (1) and press bushing
(3) to roller (1) using push tool.
q Press fitting force (Reference):
Bushing (2):
0.2 – 6.9 kN {200 – 6,900 kg}
Bushing (3):
1.6 – 11.3 kN {1,600 – 11,300kg}
2. Floating seal
1) Using tool L1, install floating seal (5) to
ring (4).
2) Using tool L1, install floating seal (6) to 3. Insert shaft (7) to roller (1) and install plate (9).
roller (1). a Apply oil to the sliding surfaces of floating
a When installing the floating seal, seal so that no dirt will be stuck.
wash the contact faces of the O-ring a Roller (1) play in axial direction:
and floating seal (shaded area), 0.4 – 0.68 mm
degrease completely and dry. The
contact surface of floating seal must
be clean without dirt.
a Using tool L1, push and insert the O-
ring to floating seal (4).
a After inserting the floating seal, check
that the seal slants by 1 mm or under
and the seal thrust capacity (a) is
within the range of 8 to 10 mm.
16 PC2000-8
4. Using the push tool L2, press the ring (4) to 8. Apply the reference pressure to the roller oil
shaft (7) so that the step between roller (1) and filling port and check the seal for the air leak-
ring (4) shall be 18.5 ± 0.2 mm. age.
a Support shaft (7) from under with push a Reference pressure: 0.1 MPa {1 kg/cm2}
tool [1].
q Press fitting force (reference):
60 – 160 kN {6,000 – 16,000 kg}
a Take care not to give large impact to the
bushing until c over ( 10) is installed
because pressed ring (4) may be mis-
aligned.
9. Tighten plug (14) after having filled the carrier

roller assembly with oil.
5 Carrier roller: 0.86 – 0.94 l (GO140)
5. Install spacer (13) and dowel pin (12).
6. Install O-ring (11) to cover (10).
7. Install cover (10) to roller (1).
PC2000-8 17
Removal and installation of 6. Remove clamps (2) and disconnect grease

revolving frame assembly 1
tubes (3).
Removal 7. Remove covers (4).

1. Remove the work equipment assembly from
the machine body, referring to "Removal and 8. Remove nipple (5).
Installation of boom assembly."
2. Remove the counterweight, referring to

"Removal and Installation of counterweight
assembly."
3. Remove the mounting bolts by leaving about 5

bolts in front and rear. [*1]
a Start the engine and remove mounting
bolts while swinging the machine.
a If the engine cannot be started, remove
the swing motors (total 2 motors in front
and rear). Then using the crane, swing
and remove the mounting bolts.
4. Remove the power container assembly, refer-

ring to "Removal and Installation of power con-
tainer assembly."
5. Remove the operator cab assembly, referring

to "Removal and Installation of operator cab
assembly."
18 PC2000-8
9. Disconnect hoses (6) to (14) from the center

swivel joint (SJ).
reinstallation.
10. Remove bar (15).
12. Remove the remaining mounting bolts, and

then lift and remove revolving frame assembly
(16). [*2]
a Provide a stopper to the slings on the back
using eyebolts to prevent them from mov-
ing away.
k Remove the revolving frame assembly
carefully by avoiding contact with the
center swivel joint assembly.
a Fuel tank deck and front swing machinery
have been removed in the picture.
a Because the swing machinery gear (SMG)
protrudes downward from the revolving
frame (portion marked with A, place the
revolving frame on top of the block of 350
mm high.
4 Revolving frame assembly:
Approx. 31,500 kg
11. Temporarily lift the revolving frame assembly.

a Two cranes are required.
a Apply protective plates, to where the

slings on the back make contact.
PC2000-8 19
Installation
removal.
[*1], [*2]
2 Swing circle mating face:
2 Threaded portion of revolving frame mount-
ing bolt:
Liquid adhesive (LT-2)
3 Revolving frame mounting bolt:
2,452 – 3,040 Nm {240 – 310 kgm}

a Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
q Bleeding air
a Bleed air, referring to "Bleeding air from each
part" in Testing and adjusting.
20 PC2000-8
Removal and installation of 5. Lift and remove counterweight assembly (2).

counterweight assembly 1
[*2]
4 Counterweight assembly: 24,000 kg
Removal
Installation
2. Remove cover (4) from the top of counter- q Carry out the installation in the reverse order of
weight assembly (2). removal.
3. Temporarily lift counterweight assembly (2) [*1]

using shackles [1]. 3 Mounting bolt:
3,430 – 4,212 Nm {350 – 430 kgm}
[*2]
a Install so that clearance to the power container
assembly shall be uniform to the left and right.

a M42 x 3 (Width across flats: 65 mm)
PC2000-8 21
SEN02137-00
© 2006 KOMATSU
All Rights Reserved
22
SEN02138-00
PC2000-8

PC2000-8 20001 and up
Hydraulic system
Hydraulic system............................................................................................................................................. 2
Removal and installation of hydraulic tank assembly........................................................................... 2
Removal and installation of hydraulic pump assembly ........................................................................ 5
Removal and installation of hydraulic pump input shaft oil seal ......................................................... 10
Removal and installation of control valve assembly............................................................................11
Disassembly and assembly of control valve assembly ...................................................................... 18
Removal and installation of center swivel joint assembly .................................................................. 22
Disassembly and assembly of center swivel joint assembly .............................................................. 23
Removal and installation of swing motor assembly ........................................................................... 24
Removal and installation of travel motor assembly ............................................................................ 25
Disassembly and assembly of work equipment PPC valve assembly ............................................... 26
Disassembly and assembly of travel PPC valve assembly................................................................ 28
Disassembly and assembly of hydraulic cylinder assembly............................................................... 29
PC2000-8 1
Hydraulic system 1

hydraulic tank assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name

799-703-1100 Vacuum pump (100 V) t 1
X 3 799-703-1111 Vacuum pump (220 V) t 1
799-703-1121 Vacuum pump (240 V) t 1
799-703-1401 Gas leak detector t 1 3. Lift and remove hand rail (2) and floor (3).
Removal
k Loosen the hydraulic tank cap gradually to
release the internal pressure.
battery before starting with the work.
k Collect air conditioner gas (R134a) before
disconnecting the hose.
k If the air conditioner gas (R134a) gets
inside one's eyes, it may cause blindness.
Therefore, make sure to wear protective 4. Disconnect clamps (4) and (5) and disconnect
glasses when collecting or filling the gas. 4 air conditioner hoses (6) from the right side
Collecting and filling work must be con- of the fuel tank assembly.
ducted by a qualified person.
a Fasten tags to pipes to identify them and show a Fasten tags to hoses to identify them for
their installation position. This helps prevent reinstallation.
any mistakes when re-installing. a Clamp is provided to the hose (14).
1. Drain hydraulic tank. 6. Remove cover (17).

2. Disconnect 4 air conditioner hoses (1) from

under floor at the entrance of the operator cab.
[*1]
reinstallation.
2 PC2000-8
7. Disconnect connectors P39 (18), P22 (19) and 10. Disconnect connector P40 (24) and harness
P38 (20) from the bottom of the cover (17). (25) from the rear of the hydraulic tank assem-
bly (29).
8. Disconnect clamp (21).
11. Disconnect connectors S23A (26) and S23B

9. Disconnect suction tubes (22) and (23). (27) and disconnect harness (28).
12. Temporarily lift hydraulic tank assembly (29).
13. Remove 12 mounting bolts (M30) (30) and

remove hydraulic tank assembly (29). [*2]
4 Hydraulic tank assembly:
Approx. 1,700 kg
PC2000-8 3
Installation q Bleeding air

q Carry out the installation in the reverse order of Bleed air from the travel motor, referring to
removal. "Bleeding air from each part" in Testing and
adjusting.
[*1]
a When installing the air conditioner circuit q Filling of refrigerant
hoses, use care so that dirt, water, may not Using tool X3, fill the air conditioner circuit with
enter. the refrigerant (air conditioner gas: R134a).
a Make sure before the installation that there is a Filling amount: 950 ± 50 g
O-ring at the piping connector of the air condi- (per one air compressor)
tioner hose. a Two air compressors are used.
a Check that there is no defect or deterioration
on the O-ring.
a When connecting the piping for refrigerant,
apply the compressor oil for the new refriger-
ant to the O-ring (Denso: ND-OIL8 or ZEXEL:
ZXL100PG (PAG46 or equivalent)).
3 Hose thread M16 × 1.5 (Width across flats

19): 12 – 15 Nm {1.2 – 1.5 kgm}
24): 20 – 25 Nm {2.0 – 2.5 kgm}
27): 30 – 35 Nm {3.0 – 3.5 kgm}
3 M6 bolt for piping (Width across flats 10):
8 – 12 Nm {0.8 – 1.2 kgm}
[*2]
3 Hydraulic tank mounting bolt:
1,520 – 1,910 Nm {155 – 195 kgm}

3 Hydraulic tank drain plug:
127.4 – 176.4 Nm {13 – 18 kgm}
Fill oil up to the specified level from the oil filler
port, start the engine to circulate oil in the pipe
and then confirm the oil level again.
5 Hydraulic tank: Approx. 1,300 l
4 PC2000-8
Removal and installation of 5. Disconnect connector A07 (100) from the

hydraulic pump assembly 1
backside of emergency engine stop switch -
front (SWF).
Removal
k Lower the work equipment completely to 6. Remove front covers (5).
k Loosen the hydraulic tank cap gradually to 7. Remove upper covers (6) and (7).
release the internal pressure. a SWF: Emergency engine stop switch -
k Lock the work equipment lock lever. front
battery before starting with the work.
1. When the oil stopper is not used, drain the

hydraulic oil.
2. Remove air cleaner upper cover (1).
3. Remove clamps (2), and then pull out 2 tubes

(3). [*1]
8. Disconnect connector A08 (8) and ground TM1

(9) from the inside of emergency engine stop
switch - behind (SWB).

a SWB: Emergency engine stop switch -
behind
9. Disconnect connector L05B (10) from the bot-

tom of SWB.
PC2000-8 5
10. Disconnect air cleaner hose (11). [*1] 14. Remove cover (A) area.
11. Sling and remove hood assembly (12). a Pump locations

4
q (17): No. 1 main pump assembly
Hood assembly: 210 kg
q (25): No. 2 main pump assembly
q (35): Fan pump assembly (middle
12. Remove air cleaner (13). lower)
13. Remove frame (14).
6 PC2000-8
No. 1 main pump assembly (17)

15. Disconnect connectors V12 (13) and V11 (15)
from inside the No.1 main pump assembly
(17).
17. Disconnect hoses (18) of both sides from the

No.1 main pump assembly (17).
19. Disconnect delivery hoses (20).
21. Disconnect suction tube (22).
22. Remove drain branch hose (23).
23. Remove fan guard (24).
24. Lift and remove No.1 main pump assembly

(17) described below. [*2]
1) Move the pump toward the fan, and dis-
connect the spline.
2) Rotate the main pump assembly 90°.
3) Lift the main pump assembly.
4 No. 1 main pump assembly: 500 kg
PC2000-8 7
No. 2 main pump assembly (25)

from the No. 2 main pump assembly.
28. Disconnect 2 delivery hoses (30).
30. Remove drain branch hose (33).
31. Disconnect suction tube.
32. Remove fan guard (34).
33. Lift and remove No.2 main pump assembly

(25) described below. [*2]
1) Move the pump toward the fan, and dis-
connect the spline.
2) Rotate the main pump assembly 90°.
3) Lift the main pump assembly.
4 No. 2 main pump assembly: 500 kg
Fan pump assembly (middle lower) (35)

34. Disconnect connector P35 (36) from the fan
pump assembly (35).
8 PC2000-8
35. Disconnect connector P34 (38) from the fan Installation

pump assembly (35). q Carry out the installation in the reverse order of
removal.
[*1]
37. Disconnect hoses (40) to (45). 3 Air cleaner hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
3 Main pump mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[*3]
3 Fan pump mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}

from the fan pump assembly (35).
39. Disconnect suction tube (48).
40. Lift and remove fan pump assembly (35). [*3]

6 Fan pump assembly: 220 kg
PC2000-8 9
Removal and installation of Installation

hydraulic pump input shaft oil q Carry out the installation in the reverse order of
removal.
seal 1
Special tools [*1]

2 Oil seal lip: Grease (G2-LI)
Necessity
a
Symbol
Apply a thin coat of grease (G2-LI) on the out-
Sketch
Q’ty
N/R
Part number Part name side perimeter of the oil seal, and press it.
a Using tool S and [1], press the oil seal (3).
S 796T-867-1810 Push tool t 1 N
Removal
1. Remove main pump assembly, referring to
"Removal of hydraulic pump assembly."
a This step is common for both No. 1 main
pump assembly and No. 2 main pump
assembly.
2. Remove snap ring (1).
3. Remove spacer (2).
4. Remove oil seal (3). [*1]
10 PC2000-8
Removal and installation of Rear overview

control valve assembly 1
Removal
hydraulic tank.
k Release remaining pressure in hydraulic
adjusting.
lock position.
k Disconnect the negative (–) terminal of the
battery beforehand.
a Fasten tags to pipes to identify them and show

their installation position. This helps prevent
any mistakes when re-installing.
Front overview
1. Drain hydraulic tank.

PC2000-8 11
Right side
2. Disconnect left PPC cutoff valve (1) from the
mounting bracket as follows.
a The mounting bracket straddles on both
right-and-left control valves. When you
remove the bracket from the left side, it
will remain connected to the right control
valve and the right PPC cutoff valve.
1) Disconnect hose clamps (2) from the top
of the control valve.
2) Disconnect hoses (3) to (5).
q (3): Without collar band
q (4): Brown/black
q (5): Brown/yellow
3) Disconnect hose (6) and other hoses 4. Disconnect following hoses from the right PPC
underneath of it. cutoff valve (13).
q (6): White/black 1) Disconnect hose (14) and other hoses
q Underneath of (6): White/yellow underneath of it. From the top:
4) Disconnect hoses (7) to (10). q Brown/brown
5) Disconnect hose clamp (11) from the q Green/red
bracket (12). q Blue
6) Remove PPC cutoff valve (1). q Red/red
q Black
3. Remove the left mounting bolt of the bracket 2) Disconnect hose (15) and other hoses
(12), and disconnect the bracket (12) from the underneath of it. From the top:
left control valve. q Brown
q Green/brown
q Blue/white
q Red/brown
q White/black
3) Disconnect hose (16) (yellow).
4) Disconnect hose (17) and other hoses
underneath of it. From the top:
q Brown
q Green
q Blue
q Red
q Black
5) Disconnect hose clamp (18).
12 PC2000-8
Front right side Control valve rear right side

5. Disconnect connectors P32 (19) and P33 (20) 14. Disconnect hoses (32) to (35).
from the filter on top of the control valve. q (32): White
6. Disconnect hoses (21) to (23). q (34): White/red
7. Disconnect hose (24) and other hoses under-
neath of it. From the top:
q Blue
q Green
q White
q Without collar band
q Black
8. Disconnect hoses (25) (brown) and (26)
(None).

From the top:
q Arm cylinder (head side)
q Boom cylinder (head side)
q Bucket cylinder (head side)
q Swing motor (left)
q Travel motor (right forward)

q Swing motor (S)

q White/blue
q White/white
q Black/white
PC2000-8 13
15. Disconnect hoses (36) and (37). 26. Disconnect valve and bracket assembly (50)
from the bottom of the filter and bracket
16. Disconnect hoses (38) to (40). assembly (47).
q (39): Red 27. Disconnect hose (51) that connects to the
q (40): Without collar band hydraulic tank.
17. Disconnect 4 hoses (41). From the top: 28. Disconnect connector P36 (52).
q Yellow
q Brown 29. Disconnect the hose clamp and harness clamp
q Black which connect to the control valve assembly
q Blue (54).
18. Remove bracket (42). 30. Remove 8 mounting bolts (53), and then lift
and remove control valve assembly (54). [*1]
4
Control valve assembly: 1,750 kg
From the top:
q Arm cylinder (bottom side)
q Boom cylinder (bottom side)
q Bucket cylinder (bottom side)
q Swing motor (right)
q Travel motor (right reverse)
20. Disconnect connector P37 (44) from the bot-

tom.
22. Disconnect connector BV1 (46) (mating part:

V19) from the filter and bracket.
23. Disconnect filter and bracket assembly (47).
24. Disconnect 5 hoses (48). From the top:

q White/yellow
q White/black
q Red
q White/blue
14 PC2000-8
Left side 8. Disconnect hose (71).

neath of it, from the PPC cutoff valve (62). 10. Remove the mounting bolt of the right PPC
From the top: cutoff valve (62) and disconnect the right PPC
q Brown cutoff valve (62) from the bracket (73).
q Green a Put aside right PPC cutoff valve.
q Blue
q Red 11. Remove the right mounting bolt of the bracket
q Black (73), and disconnect the bracket (73) from the
right control valve.
3. Disconnect hose (64) and other hoses under- a The mounting bracket straddles on both
neath of it. From the top: right-and-left control valves. When you
q Brown/black remove the bracket from the left side, it
q Yellow/brown will remain connected to the right control
q Blue/brown valve and the right PPC cutoff valve.
q White/brown
q Green/brown

q Black
q Yellow
q Blue
q White
q Green
PC2000-8 15
Front left side 21. Disconnect connectors P25 (85) and P26 (86)
12. Disconnect hoses (74) and (75). from the filter on top of the control valve.

q Brown/blue
q Green/brown
q White/brown
q Red/brown

23. Disconnect hoses (91) to (96). From the top:
18. Disconnect hose (82) and other hoses under- q (91): Without collar band
neath of it. From the top: q (92): Red/yellow
q Blue/red q (93): Without collar band (both lines)
q Green/red q (94): Black/red
q White/red q (95): Without collar band
q Without collar band q (96): Green/red
q Red/red
From the top: 25. Disconnect connector P28 (98) from the bot-
q Arm cylinder (head side) tom of the control valve.
q Boom cylinder (head side)
q Bucket cylinder (head side) 26. Disconnect hoses (99) (Without collar band)
q Travel motor (left forward) and (100) (Blue).
20. Remove mounting bolt and disconnect valve 27. Disconnect valve and bracket assembly (101).
(84).

From the top:
q Arm cylinder (bottom side)
q Boom cylinder (bottom side)
q Bucket cylinder (bottom side)
q Travel motor (left reverse)

q Brown/yellow
q Brown/brown
q Black/brown
q Green/brown
31. Disconnect connector P27 (105) from the bot-

tom of the control valve.
16 PC2000-8
33. Remove 8 mounting bolts (107), and then lift Installation

and remove control valve assembly (108). [*2] q Carry out installation in reverse order of
4
removal.
Control valve assembly: 1,750 kg
[*1], [*2]
3 Control valve bracket mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}

3 Hydraulic tank drain plug:
127.4 – 176.4 Nm {13 – 18 kgm}
5 Hydraulic tank: Approx. 1,300 l
q Bleeding air
Bleed air from the parts, refer to “Bleeding air
from various system” in Testing and adjusting.
PC2000-8 17
Disassembly and assembly of

control valve assembly 1
a This section describes precautions only for

assembly of control valve.
a For information on the tightening torque, refer
to "Structure, function and maintenance stan-
dard."
2 Mating face (F1, F2, F3, F4):

Seal end 242 or equivalent
q L1: L1 valve
q L2: L2 valve
q Left 10-spool valve
q L1 valve
1. Care should be taken for that spool, arm Lo
(AML), Boom Lo (BML) and bucket Hi (BH) are
directional.
2. Degrease and dry the threaded portions of the

valve and plug (PL).
18 PC2000-8
3. Apply two drops (approx. 0.04 g) of Loctite

(No. 638) to the threaded portion of the plug
(PL).
2 Threaded portion of the plug (PL):
2 drops (approx. 0.04 g) of Loctite (No. 638)
4. After tightening the plug (PL), keep it in station-
ary standing for 2 hours or longer.
q L2 valve
5. Core should be taken for that spool, arm Hi
(AMH), boom Hi (BMH) and bucket Lo (BL) are
directional.
6. For installation of plug (PL), refer to the "L1

valve".
PC2000-8 19
q Right 10-spool valve

2 Mating face (F3, F4):
Sealend 242 or equivalent
q R1: R1 valve
q R2: R2 valve
q R1 valve
7. Care should be taken for that spool, arm Lo
(AML), boom Hi (BMH) and bucket Lo (BL) are
directional.

valve".
20 PC2000-8
q R2 valve
9. Care should be taken for that spool, Arm Hi
(AMH), boom Lo (BML) and bucket Hi (BH) are
directional.

valve".
PC2000-8 21
Removal and installation of center 5. Disconnect hoses (14) to (22).

swivel joint assembly 1
6. Remove 4 mounting bolts (23).
7. Lift and remove center swivel joint assembly
Removal (24).
4 Center swivel joint assembly: 150 kg
hydraulic tank.
adjusting.
lock position.

1. To remove the center swivel joint assembly
(24), remove the swing motor and swing
Installation
machinery assembly - front (SMF), referring to q Carry out installation in reverse order of
"Removal and installation of swing motor and removal.
swing machinery assembly."
(SMB: Swing motor and swing machinery [*1]
assembly - behind) a A: Right travel (forward)
2. Disconnect hoses (1) to (10). B: Right travel (reverse)
a Fasten tags to hoses to identify them for C: Left travel (forward)
reinstallation. D: Left travel (reverse)
3. Remove pin (11) and move bar (12). P: Drain
4. Remove nipple (13). T: Drain
q Top view

a Add oil through oil filler to the specified level.
q Bleeding air
a Bleed air from the parts, refer to “Bleeding air
from various system” in Testing and adjusting.
22 PC2000-8
Disassembly and assembly of

center swivel joint assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
790-101-2501 Push puller t 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
T 790-101-2540 • Washer 1 Assembly
790-101-2630 • Leg 2
a See the left figure.
790-101-2570 • Plate 4
790-101-2560 • Nut 2 1. Assemble 6 slipper seals (8) to the swivel rotor
790-101-2660 • Adapter 2 (4).
2. Using push tool [2], install oil seal (7) to the
Disassembly swivel rotor (4).
4
1. Remove cover (1). Oil seal lip: Grease (G2-LI)
2. Remove snap ring (2).
3. Using tool T1, pull out the swivel rotor (4) and 3. Install snap ring (6).
ring (3) from the swivel shaft (5). 4. Set swivel shaft (5) to the block. Using push
4. Remove snap ring (6) and oil seal (7) from the tool [3], install the swivel rotor (4) by hitting with
swivel rotor (4). a plastic hammer.
5. Remove 6 slipper seals (8) from the swivel 2 Rotor-to-shaft contact surface:
rotor (4). Grease (G2-LI)

a Be extremely careful not to damage the
dust seal or O-ring when installing the
rotor.
5.Install ring (3) and fix with snap ring (2).

6.Install O-ring and install cover (1).
3 Mounting bolt: 58.8 – 73.6 Nm {6 – 7.5 kgm}
PC2000-8 23
Removal and installation of swing Rear side

motor assembly 1 6. Disconnect connector BV1 (9) (mating part:
V19).
Removal 7. Disconnect 2 hoses (10).
k Lower the work equipment completely to a Fasten tags to hoses to identify them for
the ground. reinstallation.
k Stop the engine. 8. Remove filter and bracket assembly (11).
k Release remaining pressure in hydraulic 9. Disconnect hose (12).
circuit, referring to "Releasing remaining a SM: Swing motor and swing machinery
pressure in hydraulic circuit" in Testing and assembly - behind
adjusting.
lock position.
k Loosen the oil filler cap of the hydraulic
tank to release the internal pressure of the
hydraulic tank.

a Two swing motor assemblies are used (front
and rear).
Front side
1. Remove 6 work equipment hoses (1).
q For further removal steps, refer to Step 2
to 5 in the front side.
Installation
removal.
[*1]
4 Swing motor assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

2. Disconnect hoses (2) to (4). through the system. Then, check the oil level
3. Remove step (5). again.
4. Temporarily lift swing motor assembly (6).
5. Remove mounting bolt (7), and then lift and q Bleeding air
remove swing motor assembly (6). [*1] Bleed air from the swing motor, referring to
4 Swing motor assembly: 115 kg "Bleeding air from each part" in Testing and
adjusting.
24 PC2000-8
Removal and installation of travel 2. Disconnect hoses (2) to (4).

motor assembly 1
Removal
k Swing the work equipment by 90° and lower
it completely to the ground.
k Stop the engine.
adjusting.
lock position.
k Loosen the oil filler cap of the hydraulic
tank to release the internal pressure of the
hydraulic tank. 3. Temporarily lift travel motor assembly (5).
a For the "Disassembly and assembly of travel 4. Remove mounting bolt, and then lift and
motor", refer to the "PPM Disassembly and remove travel motor assembly (5).
Assembly Procedures, Centralized Mainte-
nance Manual." 4 Travel motor assembly: 150 kg
English book No. : EEA00041-0*
* denotes a revision number.


4 Cover: 135 kg
Installation
removal.
[*1]
3 Mounting bolt:
385 ± 42 Nm {39 ± 4 kgm}

again.
q Bleeding air
Bleed air from the travel motor, referring to
"Bleeding air from each part" in Testing and
adjusting.
PC2000-8 25
Disassembly and assembly of Assembly

work equipment PPC valve q Work equipment PPC valve assembly
a Install spring (8) with its small (inside) diameter
assembly 1
end on the shim (10) side.
a Springs (11) having different numbers of turns
a In this section, only precautions for assembling are used for the following hydraulic ports. Take
the work equipment PPC valve assembly are care when installing them.
explained. a Installed height (34 mm), Spring constant: 0.98
Nm {0.1 kg/mm}
(Common to P1, P2, P3, and P4)
Port Installed load
P1, P2 3.92 N {0.4 kg}
P3, P4 11.76 N {1.2 kg}
aThe location of each port is stamped at the

lower part of the valve body.
2 Piston (7): Grease (G2-LI)
aWhen installing piston (7), apply grease to the

outside of the piston and inside of the body
hole.
3 Mounting bolt (3) of plates (5) and (6):
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
2 Sliding part of joint (4):
Grease of 2 – 4 cc (G2-LI)
aDegrease the male threads of joint (4) and

female threads of body (12) thoroughly, and
then dry them.
2 Female threads of body:
Adhesive (THREEBOND No. 648)
aApply 1 drop (about 0.02 g) of LOCTITE each

to 2 places of the female threads of the body
as shown in the figure.
3 Joint (4): 39 – 49 Nm {4 – 5 kgm}
a Observe the tightening torque for the joint.
26 PC2000-8
2 Contacting surfaces of piston and disc (2):

Grease of 0.3 – 0.8 cc (G2-LI)
3 Nut (1): 69 – 78 Nm {7 – 8 kgm}
a After installing the disc, see Testing and adjust-

ing, “Adjusting work equipment, swing PPC
valve”.
a Take care of the direction of piston (11).
3 Mounting bolt (14) of cover (13):
19.6 – 27.5 Nm {2.0 – 2.8 kgm}
PC2000-8 27
Disassembly and assembly of 7. Tighten each part to the following torque.

travel PPC valve assembly 1
q Plug (11): 34 – 44 Nm {3.5 – 4.5 kgm}
q Plug (12): 9.8 – 14.7 Nm {1 – 1.5 kgm}
q Screw (15):
a In this section, only precautions for assembling 0.441 – 0.588 Nm {0.045 – 0.06 kgm}
the travel PPC valve assembly are explained. q Bolt (16): 25 – 31 Nm {2.5 – 3.2 kgm}
Assembly q Bolt (17): 27 – 34 Nm {2.8 – 3.5 kgm}
a Clean and check the parts so that dirt, rust, q Plug (18): 6 – 11 Nm {0.6 – 1.1 kgm}
flaws, etc. will not cause a trouble and then q Plug (19): 4 – 9 Nm {0.4 – 0.9 kgm}
assemble them with extreme care.
1. When assembling piston (1), apply grease

(G2-LI) to the outside of the piston and inside
of the body hole.
2. Install spring (2) with its small diameter end on

the shim (3) side.
q Diameter of (Inside diameter) of spring
Small diameter end: ø4.9 mm
Large diameter end: ø5.54 mm
3. Do not insert bushing (4) by hitting it with a

hammer directly.
4. Do not insert pin (5) by hitting it with a hammer

directly.
5. Apply grease (G2-LI) to the rocking parts of

shaft (6), contacting parts of lever (7) and pis-
ton (1), and contacting parts of the lever of
damper (9) and pin (8).
2 Quantity of grease (G2-LI) to be applied
Rocking parts of shaft (6):
4 – 8 cc/periphery
Contacting parts of lever (7) and piston (1):
0.3 – 0.8 cc/part
Contacting parts of lever of damper (9)
and pin (8): 0.3 – 0.8 cc/part
6. Install washer (10) 1.6 mm thick first. If the dif-

ference of the lever stroke angle between the
right and left exceeds 0.7°, replace the washer
with one of different thickness to reduce the
difference below 0.7°. (If the washer thickness
is reduced by 0.3 mm, the stroke angle is
increased by 0.39°.)
a Install one of washers (10).
q Thicknesses of washers:
1.0, 1.3, 1.6, 1.9, 2.2 mm
28 PC2000-8
Disassembly and assembly of 3) Pull out piston rod assembly (2).

hydraulic cylinder assembly 1
a Place a container under the cylinder
to catch the oil.
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Cylinder repair
790-502-1003 t 1
1 stand
790-101-1102 Pump t 1
790-102-4300 Wrench assembly t 1
2
790-102-4310 Pin t 2
3 790-720-1000 Expander t 1
796-720-1690 Ring (for bucket) t 1
07281-02169 Clamp t 1
4) Disassemble piston rod assembly as fol-
796-720-1710 Ring (for arm) t 1
4 lows.
07281-02709 Clamp t 1 1] Set piston rod assembly (2) to tool
796-720-1730 Ring (for boom) t U1.
07281-03209 Clamp t
790-201-1702 Push tool kit t 1
• Push tool
790-201-1881 1
(for bucket)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Push tool
U 791-863-1110 t 1
5 (for arm)
790-101-5421 Grip t 1
01010-51240 Bolt t 1
Push tool
792-630-1300 t 1
(for boom)
790-101-5421 Grip t 1 2] Remove piston assembly stopper
01010-51240 Bolt t 1 screw (3).
Screw size:
Push tool kit
790-201-1500 t 1 M12 × pitch 1.75: Arm, Bucket
(for bucket)
M16 × pitch 2 : Boom
790-201-1640 • Push tool 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6 792-715-1400 Plate (for boom) t 1
790-101-5421 Grip t 1
01010-51240 Bolt t 1
790-445-4220 Plate (for arm) t 1
790-101-5421 Grip t 1
01010-51240 Bolt t 1
Disassembly
1. Piston rod assembly
1) Remove piping from cylinder assembly.
2) Remove mounting bolts, and disconnect
head assembly (1).
PC2000-8 29
a If screw (3) has been caulked

strongly and cannot be removed,
screw it in fully, then fit a tap to
the thread and pull it out.
7] Remove cap (8), and pull out balls

(9), then remove cushion plunger
(10).
q Balls (9): 10 balls (Arm cylinder)
3] Using tool U2, remove piston assem- 11 balls (Bucket cylinder)
bly (4). a Except boom cylinder
q When not using tool U2, use the
drill holes (H) (2 places) and
loosen the piston assembly.
a Drill holes
ø10 mm (Bucket, Arm)
ø16 mm (Boom)
2. Disassembly of piston assembly

1) Remove ring (11).
2) Remove wear ring (12).
a 2 pieces are installed to each of the
boom cylinder, and 4 pieces to the
bucket cylinder and arm cylinder.
4] Remove plunger (5). (Boom, bucket 3) Remove piston ring (13).
only) 4) Remove O-ring and backup ring (14).
5] Remove collar (6). (Boom, bucket q Boom cylinder
only)
6] Remove head assembly (7).
30 PC2000-8
q Arm cylinder, bucket cylinder Assembly

a Be careful not to damage the packings, dust
seals, and O-rings.
a Do not try to force the backup ring into posi-
tion. Warm it in warm water (50 – 60°C) before
fitting it.
1. Assembly of cylinder head assembly

1) Using tool U5, press fit bushing (20).
2) Assemble buffer ring (19).
3) Assemble rod packing (18).
4) Using tool U6, install dust seal (17), and
secure with snap ring (16).
5) Install backup ring and O-ring (15).
3. Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (15).
2) Remove snap ring (16), then remove dust
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
PC2000-8 31
2. Assembly of piston assembly 3. Piston rod assembly

1) Using tool U3, expand piston ring (13). 1) Set piston rod assembly (2) to tool U1.
a Set the piston ring on tool U3, and
t ur n th e h an d le 8 – 1 0 t im e s t o
expand the ring.
2) Set tool U4 in position, and compress pis-
ton ring (13).
2) Assemble head assembly (7).

3) Fit O-ring and backup ring to collar (6),
then assemble.
q Boom cylinder and bucket cylinder
only
3) Install backup ring and O-ring (14). 4) Assemble plunger (5).
4) Assemble wear rings (12). q Boom cylinder and bucket cylinder
5) Assemble rings (11). only
a Be careful not to open the end gap of
the ring too wide.
2 Ring groove: Grease (G2-LI)
q Boom cylinder
q Arm cylinder, bucket cylinder
32 PC2000-8
5) Set cushion plunger (10) to piston rod, 2] Tighten screw (3).

then assemble balls (9), and secure with 2Threaded part:
cap (8). Thread tightener
q Balls (9):10 balls (Arm cylinder) (Locktite No. 262 or equivalent)
11 balls (Bucket cylinder) 3 Screw:
a Except boom cylinder 58.9 – 73.6 Nm {6 – 7.5 kgm}
a Put a mark on the end surface of the (arm and bucket)
rod so that the machined hole posi- 98 – 123 Nm {10 – 12.5 kgm}
tion on the cap (8) can be identified (boom)
from outside. 3] Caulk thread at 4 places (a) of
a After installing, check that the cushion screw (3) with punch.
plunger end has a little play.
q When using a new part for either or

6) Assemble piston assembly (4) as follows. both of rod assembly (2) or piston
q When using rod assembly (2) and pis- assembly (4)
ton assembly (4) again a For the rod with bottom cushion,
a Wash thoroughly and remove all mark the cushion plug position
metal particles and dirt. on the end face of the rod.
1] Screw in piston assembly (4), (See the item of 3. 5)
then use tool U2 to tighten piston q Arm cylinder, bucket cylinder
assembly so that position of only
screw thread hole matches. 1] Screw in until piston assembly
a Remove all burrs and flashes (4) contacts end face of rod, then
with a file. use tool to tighten.
3 Piston assembly (4):
294 ± 29.4 Nm {30 ± 3.0 kgm}
a After tightening the piston,
check that there is play in
plunger (5).
PC2000-8 33
2] Machine one hole used to install 7) Set piston rod assembly (2) to tool U1.
screw (3).
a Apply the drill to the V-groove
between piston (4) and
threaded part of rod (2), and
make a hole horizontally.
a For the cylinder with bottom
cushion (arm cylinder, bucket
cylinder), avoid the cushion
plug position when machin-
ing.
q Screw machining dimension
(mm)
Bottom
Drill Tap
Cylinder hole Tap used
diameter depth
depth 8) Assemble cylinder tube to piston rod
Bucket 10.3 43 12 × 1.75 36 assembly (2).
2 Seal portion: Grease (G2-LI)
Arm 10.3 48 12 × 1.75 44
a Set the end gap of the ring at the hor-
Boom 14 48 16 × 2 44
izontal (side) position, align the axial
3] After machining, wash thor- center of shaft and cylinder tube, then
oughly to remove all metal parti- insert.
cles and dust. a After inserting, check that the ring is
4] Tighten screw (3). not broken and has not come out,
2 Threaded part:
then push in fully.
Thread tightener
(Locktite No. 262 or equivalent)
3 Screw:
58.9 – 73.6 Nm {6 – 7.5 kgm}
(arm and bucket)
98 – 123 Nm {10 – 12.5 kgm}
(boom)
5] Caulk thread at 4 places (a) of
screw (3) with punch.
34 PC2000-8
9) Tighten head assembly (1) with mounting

bolts.
3 Mounting bolt :
Cylinder Tightening torque

Bucket 1,270 ± 200 Nm {130 ± 20 kgm}
Arm 2,110 ± 340 Nm {215 ± 35 kgm}
Boom 2,650 ± 390 Nm {270 ± 41 kgm}
10) Install piping.
PC2000-8 35
SEN02138-00
© 2006 KOMATSU
All Rights Reserved
36
SEN02139-00
PC2000-8

PC2000-8 20001 and up
Work equipment
Work equipment .............................................................................................................................................. 2
Removal and installation of bucket cylinder assembly ......................................................................... 2
Removal and installation of bucket assembly ...................................................................................... 4
Removal and installation of arm cylinder ............................................................................................. 6
Removal and installation of arm assembly........................................................................................... 8
Removal and installation of boom cylinder assembly ........................................................................ 10
Removal and installation of boom assembly ...................................................................................... 12
PC2000-8 1
Work equipment 1
Removal and installation of 5. Temporarily lift the bucket cylinder assembly,

bucket cylinder assembly 1
remove plate (6) and pull out pin (7) on the bot-
tom side. [*2]
Backhoe specification a If the pin would not be pull out, pull out the
Removal pin on the bottom side using a bolt or eye-
k Contract the arm and bucket cylinder pis- bolt.
ton rods, lower the work equipment to the
ground completely and set the lock lever to 6. Remove bucket cylinder assembly (8).
the lock position. 2 Bucket cylinder assembly: 900 kg
a After disconnecting hoses, install plugs to pre-

vent foreign matters from entering them.
1. Set block [1] between the bucket cylinder and

the arm, and block [2] between the link and the
arm respectively.
2. Remove 3 pin fastening bolts (1) inside the link

and a stopper (2), and then pull out pin (3) on
the head using a forcing screw. [*1]
3. Start the engine and contract the piston rod.

Bind the piston rod with wire to prevent it from
falling out.
4. Disconnect hose (4) and lubricating hose (5).
2 PC2000-8
Installation
removal.
[*1]
2 Internal bushing surface during pin assem-
bly:
Antifriction composition (LM-P)
2 Greasing after pin assembly:
Grease (LM-G)
k When aligning holes of the pins, absolutely
do not insert fingers into a pin hole.
[*2]
2 Internal bushing surface during pin assem-
bly:
Antifriction composition (LM-P)
2 Greasing after pin assembly:
Grease (LM-G)
k When aligning holes of the pins, absolutely
do not insert fingers into a pin hole.
q Adjust shim (10) so that the clearance (a)
between bucket cylinder (8) bottom end face
and arm (9) shall be 1 mm max.
q Shim thickness: 1.0 mm
q Bleeding air

again.
PC2000-8 3

bucket assembly 1
Removal
k Place the work equipment stably on the
ground with the back of the bucket facing
downward. Set the lock lever to the lock
position.
1. Remove 3 pin lock bolts (1), and then remove

the stopper (2).
2. Remove connecting pin (3) for the link and

bucket using a forcing screw. [*1]

Bind the link to the arm with wire to prevent the
piston rod from falling out.
4. Remove greasing piping cover (4) and discon-

nect greasing hose (5).
5. Remove 6 pin cover lock bolts (6), and then

remove pin cover (7).
6. Remove 6 pin cover lock bolts (8), and then
remove pin cover (9).
7. Remove arm connecting pin (10). [*2]
8. Start the engine, raise the work equipment,

disconnect the arm from the bucket and then
remove the bucket assembly.
2 Bucket assembly: 10,000 kg
4 PC2000-8
Installation
removal.
[*1]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the pin hole.
[*2]
a Insert the O-ring at the end face of the bucket
boss securely.
PC2000-8 5
Removal and installation of arm 5. Disconnect hose (4) and lubricating hose (5)
cylinder 1
on the bottom side.
Backhoe specification 6. Temporarily lift the arm cylinder assembly,

Removal remove the plate (6) and pull out pin (7) on the
k Extend the arm cylinder piston rod to bottom side. [*2]
approx. 200 mm before the end of excavat- a If the pin would not be pull out, pull out the
ing stroke. Lower the work equipment com- pin on the bottom side using a bolt or eye-
pletely to the ground and set the lock lever bolt.
to the lock position.
a After disconnecting hoses, install plugs to pre- 7. Remove arm cylinder assembly (8).
vent foreign matters from entering them. 4 Arm cylinder assembly: 1,300 kg
1. Set block [1] between arm cylinder (8) and the

boom.
2. Disconnect greasing hose (1) on the head

side.
3. Remove the plate (2) and then pull out the pin
(3) on the head side. [*1]
a If the pin would not be pull out, pull out the
pin on the head side using a bolt or eye-
bolt.

falling out.
6 PC2000-8
Installation q Bleeding air

q Carry out installation in the reverse order to a Bleed air, referring to "Bleeding air from each
removal. part" in Testing and adjusting.
[*1] q Refilling with oil (Hydraulic tank)

2 Inside surface of bushing when assembling a Add oil through the oil filler to the specified
pin: Anti-friction compound (LM-P) level. Run the engine to circulate the oil
2 Grease after assembling pin: Grease (LM-G) through the system. Then, check the oil level
k When aligning the position of the pin hole, again.
a Install shim (10) of 8.0 mm thick to the clear-

ance (a) between arm cylinder (8) head end
face and arm assembly (9).
[*2]
a Install shim (12) of 11 mm thick to the clear-
ance (a) between arm cylinder (8) bottom end
face and boom assembly (11).
PC2000-8 7
Removal and installation of arm 3. Disconnect greasing hose (1) from inside.
assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
796T-870-1150 Sleeve t 1 Q
796T-870-1170 Sleeve t 1 Q
796-870-1180 Adapter t 1
796T-870-1190 Plate t 1 Q
4. Remove plate (2).
796-900-1230 Screw t 1
V
01582-33024 Nut t 1 5. Temporarily lift the arm cylinder and pull out pin
01643-33080 Washer t 1 (3) on the arm cylinder head side. [*1]
Puller a If the pin would not be pull out, pull out the
790-101-4000 t 1 pin on the head side using a bolt or eye-
(1,471 kN {150 ton})
790-101-1102 Pump t 1 bolt.

Removal Bind the piston rod with wire to prevent it from
1. Remove the bucket assembly, referring to falling out.
"Removal of bucket assembly."
7. Set block [3] between the arm cylinder and the
2. Fix the link to the arm using a wire. boom, and place the arm cylinder on block [3].
k Extend the arm cylinder piston rod to
approx. 200 mm before the end of exca- 8. Disconnect 2 bucket cylinder hoses (4).
vating stroke. Lower the arm on to
block [1] and blocking tool [2]. 9. Disconnect greasing tube (5).
k Set the lock lever to the lock position
and stop engine. 10. Remove plate (6).
8 PC2000-8
Installation
removal.
[*1]
[*2]
11. Lift arm assembly (8) temporarily. 2 Grease after assembling pin: Grease (LM-G)
a Keep the arm lowered on block [1] and k When aligning the position of the pin hole,
blocking tool [2] (described above). never insert your fingers in the pin hole.
q A: Sling brackets a Adjust the clearance between boom assembly
(9) and arm assembly to 1.5 mm max. using
12. Remove boom stop pin (7) using tool V. [*2] shim (10).
q Shim thickness: 12 mm, 9 mm, 1.5 mm and
13. Run the engine and raise the boom. 1.0 mm
14. Lift and remove arm assembly (8).

4 Arm assembly (including bucket cylin-
der and link): 12,600 kg
q Bleeding air

again.
PC2000-8 9
Removal and installation of boom 5. Start the engine and contract the piston rod.
cylinder assembly 1
falling out.
Removal 6. Lower the boom cylinder assembly to a block-
k Contract the arm and bucket cylinder pis- ing tool and disconnect hoses (4).
ton rods, lower the work equipment to the
ground completely and set the lock lever to 7. Disconnect greasing hose (5).
the lock position.
a After disconnecting hoses, install plugs to pre- 8. Temporarily lift the boom cylinder assembly,
vent foreign matters from entering them. and remove lock plate (6).
1. Disconnect greasing hose (1). 9. Pull out pin (7) on the bottom side using an
eyebolt. [*2]
2. Remove lock plate (2).
10. Remove boom cylinder assembly (8).

3. Lift the boom cylinder assembly temporarily. 4 Boom cylinder assembly: 2,400 kg
4. Pull out the pin on the head side using a bolt or

eyebolt to sections (A), and disconnect the pis-
ton rod from the boom. [*1]
10 PC2000-8
Installation q Refilling with oil (Hydraulic tank)

q Carry out installation in the reverse order to a Add oil through the oil filler to the specified
removal. level. Run the engine to circulate the oil
[*1] again.
a Align the pin hole position by lifting the pin and
piston rod.
[*2]
a Adjust shim (10) so that the clearance (a)
between bucket cylinder (8) bottom end face
and arm (9) shall be 1 mm max.
q Shim thickness: 1.0 mm and 1.5 mm
a Install shim (11) of 16 mm thick to inside the
machine body on the bottom side of boom cyl-
inder (8).
q Bleeding air
PC2000-8 11
Removal and installation of boom 7. Remove lock plate (6) and then remove 2
assembly 1
boom foot pins (7) using the eyebolt. [*1]
4 Boom assembly (including arm cylin-
der): 21,000 kg
Removal
1. Remove the arm assembly, referring to
"Removal of arm assembly."
k Lower the boom to the ground com-
pletely and set the lock lever to the lock
position.
2. Disconnect the boom cylinder assembly from

the boom, referring to "Removal of boom cylin-
der assembly."
3. Disconnect headlamp wiring (1).
4. Disconnect greasing hose (2).
5. Disconnect bucket cylinder hose (3) and arm 8. Lift and remove boom assembly (5).
cylinder hose (4).
6. Lift boom assembly (5) temporarily.
12 PC2000-8
Installation
removal.
[*1]
a Adjust shim (9) so that the clearance (a)
between boom (5) foot end face and bracket
(8) shall be 1 mm max.
q Shim thickness: 1.0 mm and 1.5 mm
q Bleeding air

again.
PC2000-8 13
SEN02139-00
© 2006 KOMATSU
All Rights Reserved
14
SEN02140-00
PC2000-8

PC2000-8 20001 and up
Cab and its attachments

Cab and its attachments ................................................................................................................................. 2
Removal and installation of operator cab assembly............................................................................. 2
Removal and installation of operator cab glass (adhesion glass) ........................................................ 5
Removal and installation of operator cab (assembly-type) ................................................................ 12
Removal and installation of cab base assembly ................................................................................ 13
PC2000-8 1
Cab and its attachments 1
Removal and installation of 4. Remove plate (3) and disconnect 2 air condi-
operator cab assembly 1
tioner hoses (4). [*2]
Special tools 5. Disconnect air conditioner hose (5). [*3]
New/Remodel
6. Disconnect drain hose (6).
Sym-
Necessity
Part No. Part name
bol
Sketch
7. Disconnect connector A35 (7).
Q'ty
8. Disconnect 4 heater hoses (8).
Vacuum pump
799-703-1100 t 1
(100 V)
Vacuum pump
X 3 799-703-1111 t 1
(220 V)
Vacuum pump
799-703-1121 t 1
(240 V)
Removal
lock position.
k Disconnect the cable from the negative (–) 9. Disconnect clips (9) and washer hoses (10)
terminal of the battery. from the cab base.
R134a).
could cause blindness. Only the qualified
ing of the refrigerant.
1. Drain coolant.
6 Coolant: 180 l
2. Disconnect air conditioner hose (1) from under

the air conditioner unit. [*1]
10. Disconnect antenna wire (11) from the distribu-
tion board of the cab base.
3. Disconnect connector M84A (2).
2 PC2000-8
11. Disconnect grounding wire (12) from the cab 16. Remove the covers (17).
base ceiling.
12. Disconnect connectors (13). (Connector num-

bers read A03, A02 and A01 from the left.)
13. Disconnect PPC hoses (14). From the right

Boom lower: Brown
Boom raise: Green
Bucket dump: Black
Bucket curl: White
Arm out: Yellow

Arm in: Blue
Right swing: Without collar band
Left swing: Red 17. Remove the mounting bolts, and then lift and
remove the operator cab assembly (18). [*4]
14. Disconnect PPC hoses (15). From the right
Right lever P: Red 4 Operator cab assembly: 1,850 kg
Right lever T: Blue and blue
Left lever P: Red and white
Left lever T: Blue and white
15. Disconnect PPC hoses (16) from the front of

the cab base ceiling. From the right
Right travel forward: Blue and black
P: Red
Right travel reverse: Black and black
Left travel reverse: Red and black
T: Blue
Left travel forward: Green and black
PC2000-8 3
Installation 1. Adjust clearances (a) and (b) with the operator

q Carry out the installation in the reverse order of on board after having installed the operator
removal. cab assembly.
q Clearance for both (a) and (b): 3 mm Max.
[*1], [*2], [*3] a Shim thickness for (S1) and (S2): 1.6 mm
a Install the hoses without twisting. and 3.2 mm
a When installing the air conditioner circuit
hoses, use care so that dirt, water, may not
enter.
a Make sure before the installation that there is
O-ring (70) at the piping connector of the air
conditioner hose.
a Check that there is no defect or deterioration
on the O-ring.
a When connecting the piping for refrigerant,
apply the compressor oil for the new refriger-
ant to the O-ring (Denso: ND-OIL8 or ZEXEL:
ZXL100PG (PAG46 or equivalent)).
a When connecting the refrigerant piping, use

double spanner to tighten the piping. q Filling of refrigerant
3 Hose thread M16 × 1.5 (Width across flats Using tool X3, fill the air conditioner circuit with
19): 12 – 15 Nm {1.2 – 1.5 kgm} the refrigerant (air conditioner gas: R134a).
3 Hose thread M22 × 1.5 (Width across flats a Filling amount: 950 ± 50 g
24): 20 – 25 Nm {2.0 – 2.5 kgm} (per one air compressor)
3 Hose thread M24 × 1.5 (Width across flats a Two air compressors are used.
27): 30 – 35 Nm {3.0 – 3.5 kgm}
3 M6 bolt (width across flats: 10) for the piping:
8 – 12 Nm {0.8 – 1.2 kgm}
[*4]
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
4 PC2000-8
Removal and installation of Removal

operator cab glass (adhesion
a Remove the window glass to be replaced
glass) 1
a Of the 4 window glasses of the operator cab,
adhesive type glasses are (1) and (2) as 1. Using seal cutter [1], cut the adhesive between
shown in the figure. broken window glass (7) and operator's cab
a This section describes replacement proce- (metal sheet) (8).
dures of adhesive type glass (for the right-
hand side window glass (1)).
a For the front window glass (2), the same pro-
cedure applies as for the right-hand side win-
dow glass (1). (Difference between the right-
hand side window glass (1) is in the size and
weight.)
(1): Right-hand side window glass

(2): Front window glass
4 Right-hand side window glass: 40 kg
Front window glass: 65 kg
a If a seal cutter is not available, make holes on

the adhesive and both-sided adhesive tape
with a drill and pass a fine wire (piano wire,
etc.) [2] through the holes. Grip the both ends
of the wire with pliers [3], etc. (or hold them by
winding them onto something) and move the
wire to the right and left to cut the adhesive
and both-sided adhesive tape. Since the wire
may be broken by the frictional heat, apply
lubricant to it.
(The figure shows the operator's cab of a

wheel loader.)
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name

bol
Sketch
Q'ty
Lifter
1 793-498-1210 t 4
X (Suction cup)
2 20Y-54-13180 Adapter t 2
PC2000-8 5
a If the window glass is broken finely, it may be Installation

removed with knife [4] and a screwdriver.
a Widening the cut with a screwdriver, cut the 1. Using a knife and scraper [5], remove the
adhesive and both-sided adhesive tape with remaining adhesive and both-sided adhesive
knife [4]. tape from the metal sheets (glass sticking sur-
faces) of the operator's cab.
(The figure shows the operator's cab of a a Remove the adhesive and both-sided
wheel loader.) adhesive tape to a degree that they will
not affect adhesion of the new adhesive.
Take care not to scratch the painted sur-
f a c e s . ( I f t h e pa i n t e d s u r f a c e s a r e
scratched, adhesion will be lowered.)

wheel loader.)
2. Remove the window glass.
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (8) and window glass (9) with
white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.

wheel loader.)
6 PC2000-8
3. Apply primer (10). 3) Evenly apply paint primer to the surfaces

a The using limit of primer (10) is 4 months to stick both-sided adhesive tapes and the
after the date of manufacture. Do not use surfaces out of those surfaces on opera-
primer (10) after this limit. tor's cab (8) which will be coated with the
a Use the primer within 2 hours after adhesive.
unpacking it. 2 Paint primer:
a Even if the primer is packed again just SUNSTAR PAINT PRIMER 435-95
after it is unpacked, use it within 24 hours a Do not apply the primer more than 2
after it is unpacked for the first time. (Dis- times. (If it is applied more than 2
c a r d t h e pr im e r 2 4 ho u r s a fte r i t is times, its performance will be low-
unpacked.) ered.)
1) Stir the primers for paint and glass suffi-
ciently before using them. (The figure shows the operator's cab of
a If the primer has been stored in a PC200.)
refrigerator, leave it at the room tem-
perature for at least half a day before
stirring it. (If the primer is unpacked
just after taken out of the refrigerator,
water will be condensed. Accordingly,
leave the primer at the room tempera-
ture for a sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer glass primer.
a Parts to be coated with primer: Apply

the primer all over dimension (a).
q Dimension to apply primer (a): 30 mm
q Dam rubber (6) mounting dimension
(b): 8.5 mm
a (8): Operator’s cab
a After applying the primer, leave it for

at least 5 minutes (within 24 hours) to
dry.
a Never apply wrong primer. If the glass
primer is applied by mistake, wipe it
off with white gasoline.
PC2000-8 7
4) Evenly apply glass primer to the sticking 4. Stick both-sided adhesive tape (6) along 8.5
surfaces of window glass (9). mm off from the inside edge of the glass stick-
2 Glass primer: ing section.
SUNSTAR GLASS PRIMER 435-40 a Do not remove the release tape of the
a Do not apply the primer more than 2 both-sided adhesive tape on the glass
times. (If it is applied more than 2 sticking side before sticking the glass.
times, its performance will be low- a When sticking the both-sided adhesive
ered.) tape, do not touch the cleaned surface as
long as possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window frame.
a Parts to be coated with primer: Apply the

primer to the sticking surfaces of window
glass (9) and all over dimension (d) which
will be on both-sided adhesive tape (6) a When sticking both-sided adhesive tape
and operator's cab (8). (6) around a frame, do not lap its finishing
a Do not apply the primer to the boarder end over the starting end but make clear-
about 5 mm wide between the black part ance (e) of about 5 mm between them.
and transparent part of the glass. (This is 1) Stick both-sided adhesive tape (6) for right
because the adhesive is photoreactive.) side window glass (1) as shown in the fig-
Black glass portion is provided to shield ure.
lights (protection of adhesive agent).)
q Application dimensions (d) for glass (9)
primer: 30 mm
q Dam rubber (6) mounting dimension (b):
8.5 mm
a After applying the primer, leave it for at
least 5 minutes (within 24 hours) to dry.
a Never apply wrong primer. If the glass
primer is applied by mistake, wipe it off
with white gasoline.
8 PC2000-8
5. Position the new window glass. 6. Apply adhesive.

1) Check the clearance between the window a Use either of the 2 types of the adhesive.
glass and the operator's cab on the right, 2 Adhesive (Summer):
left, upper, and lower sides, and then SUNSTAR PENGUINE SEAL
adjust it evenly. 580 SUPER "S"
4 Right-hand side window glass: 2 Adhesive (Winter):
40 kg SUNSTAR PENGUINE SEAL
Front window glass: 65 kg 580 SUPER "W"
2) Stick tapes [6] between window glass (9) a The using limit of the adhesive is 4 months
and operator's cab (8) and draw position- after the date of manufacture. Do not use
ing line (n). the adhesive after this limit.
3) Cut the tape between window glass (9) a Keep the adhesive in a dark place where
and operator's cab (8) with a knife, and the temperature is below 25°C.
then remove the window glass. a Never heat the adhesive higher than
a Do not remove the tapes left on the 30°C.
window glass and operator's cab a When reusing the adhesive, remove the
before installing the window glass. all hardened part from the nozzle tip.
(The figure shows the operator's cab of 1) Break aluminum seal (13) of the outlet of
PC200.) adhesive cartridge (12) and install the
nozzle.
2) Cut the tip of the adhesive nozzle (14) so

that dimensions (q) and (r) will be as fol-
lows.
q Dimension (q) : 10 mm
q Dimension (r) : 15 mm
PC2000-8 9
3) Set adhesive cartridge (12) to caulking 7. Install the window glass.

gun [7]. 1) Install window glass (9), matching it to the
a An electric caulking gun is more effi- lines of the positioning tapes drawn in step
cient. 5.
a Since the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking window glass (9), press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
4) Remove the release tape of the both-

sided adhesive tape on the glass side.
5) Apply adhesive (15) to the outside of both-
sided adhesive tape (6) of the operator's
cab.
a Reconfirm that the primer is coated
on the surface to coat the adhesive,
then coat the adhesive.
a Apply adhesive (15) to dimensions (s)
and (t) of both-sided adhesive tape
(6) of operator's cab (8). a You can perform this work efficiently
q Dimension (s) : 10 mm by pulling window glass (9) from
q Dimension (t) : 15 mm inside of the operator's cab with suc-
a Apply adhesive (15) higher than both- tion cup (X1).
sided adhesive tape (6). (The figure shows the operator's cab of
a Apply the adhesive evenly. PC200.)
10 PC2000-8
8. Fix the window glass. a When cleaning the glass, do not give an
1) After installing right window glass (1) to impact to it.
the operator's cab, insert stopper rubbers
(X2) to 2 places (v) at the bottom of the 10. Protect the stuck window glass.
glass to fix the glass. 1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humid-
ity of 60%).
2) After removing the stopper rubbers, sty-
rene foam blocks, and rubber bands, wait
at least 14 hours, at least 24 hours in total,
before operating the machine actually.
11. Install window frame (17).
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and both-
sided adhesive tape to fit them completely.
(The figure shows the operator's cab of
PC200.)
9. After installing the window glass, remove the

primer and adhesive from the operator's cab
and window glass.
a Using white gasoline, wipe off the adhe-
sive before it is dried up.
PC2000-8 11
Removal and installation of 2. Remove window glass (6) as follows:

operator cab (assembly-type) 1
1) Remove 33 bolts (4) to remove frame (3)
assembly.
2) Remove 4 screws (5) bolts each from Y
Removal and Z to disassemble frame (3).
3) Remove window glass (6).
a This section describes replacement procedure
for assembly-type window glass (left hand win-
dow glass (1), (2) and (6)).
1. Remove window glass (1) and (2) as follows:

1) Lift window glass (1) and (2) and separate
them from the lower frame (F).
2) Remove window glass (1) and (2) by tilting
them sideways.
Installation

removal.
12 PC2000-8
Removal and installation of cab

base assembly 1
Removal
1. Remove the operator cab assembly, referring

to "Removal and installation of operator cab
assembly."
2. Remove hand rail (1) and floor (2).
3. Disconnect PPC hoses (3). From the top
9. Pull out harness (11) from the cab base.

(See the preceding section)
10. Disconnect connectors A05 (12), A04 (13) and

A22 (14).
4. Disconnect connectors A11 (4), A12 (5), A25

(6) and A10 (7) from right rear of the cab base.
12. Temporarily lift cab base assembly (16).

a Special brackets (A) are provided.
6. Disconnect 7 connectors (9) from left rear of

the cab base. From the top
B01, B02, B03, B04, B05, A27, A24

(See the following section)
PC2000-8 13
13. Remove mounting bolts (17) under the cab 15. Lift and remove cab base assembly (16).
base. [*1] a Work equipment is not installed in the pic-
ture.
4 Cab base assembly: 2,000 kg
14. Remove mounting bolts (18) in the middle (and

right-hand side) of the cab base. [*2]
Installation
removal.
[*1], [*2]
3 Mounting bolts:
455 – 565 Nm {46.5 – 58 kgm}
a Cab base mounting bolts
14 PC2000-8
SEN02140-00
© 2006 KOMATSU
All Rights Reserved
16
SEN02141-00
PC2000-8

PC2000-8 20001 and up
Electrical system
Electrical system ............................................................................................................................................. 2
Removal and installation of air conditioner unit assembly ................................................................... 2
Removal and installation of monitor assembly ..................................................................................... 6
Removal and installation of engine controller assembly ...................................................................... 7
Removal and installation of pump controller assembly ........................................................................ 8
Removal and installation of pump controller assembly ........................................................................ 8
Removal and installation of VHMS controller assembly....................................................................... 9
Removal and installation of Orbcomm terminal assembly for VHMS................................................... 9
PC2000-8 1
Electrical system 1
Removal and installation of air

conditioner unit assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
Vacuum pump
799-703-1100 t 1
(100 V)
Vacuum pump
X 3 799-703-1111 t 1
(220 V)
4. Remove covers (5), (6) and (7).
Vacuum pump
799-703-1121 t 1
(240 V) 5. Remove ducts (8) and (9).
Removal
lock position.
battery beforehand.
R134a).
could cause blindness. Only the qualified 6. Disconnect connector M84B (10) from under.
ing of the refrigerant. 7. Remove plate (11) and disconnect 2 air condi-
tioner hoses (12) and (13). [*1]
1. Drain coolant.
6 Coolant: 180 l 8. Disconnect 2 heater hoses (14).

2. Remove covers (1) and (2) from the rear of the
operator's cab. 10. Disconnect connector A35 (16).
3. Remove outside air filters (3) and plate (4).
2 PC2000-8
11. Remove duct (17) for the foot. 19. Remove ducts (30) and (31).
12. Disconnect clips (18) and (19).
15. Disconnect grommet (22).
20. Remove face duct (32) and rear duct (33).

a Before removing both ducts (32) and (33),
remove their mounting bolts.
16. Disconnect connector M84A (23).
17. Remove plate (24) and disconnect two air con-

ditioner hoses (25). [*2]
18. Disconnect connectors M33A (26), M27A (27),

M33B (28) and M27B (29).
21. Remove defroster ducts (34) and (35).
PC2000-8 3
22. Remove air conditioner unit (36). 27. Remove air conditioner unit (44).
a (44): Underside of air conditioner unit
Reference
23. Remove defroster duct (37) and rear duct (38). a D1 and D2 are equipped with the following
ducts:
24. Remove bracket (39) and face duct (40). D1: Foot duct
D2: Foot duct, rear duct and defroster duct
a The air blow from upper and lower air con-
ditioner units is mixed by these ducts and
the already removed ducts, and is sent to
the operator's cab.
25. Remove face duct (41).
26. Remove defroster ducts (42) and (43).
q Conceptual diagram of air conditioner and

duct layout
a FCD: Face duct
RD: Rear duct
DD: Defroster duct
FD: Foot duct
4 PC2000-8
a DD: Defroster duct Installation

FD: Foot duct q Carry out the installation in the reverse order of
F: Inside air filter removal.
[*1], [*2]
a Take care to prevent the hose of the air condi-
tioner circuit from entry of dusts, dirt or water.
a Before proceeding to the installation, check
that the O-ring is provided at the air conditioner
hose connection.
a Check the O-ring for scratches or degradation.
a When connecting the air conditioner hose,
apply the O-rings with the compressor oil for
coolant R134a (Denso: ND-OIL8 or Zexel:
ZXL100PG (PAG46 or equivalent)), and
tighten them with a double wrench.
3 M6 bolt (width across flats: 10) for the piping:
8 – 12 Nm {0.8 – 1.2 kgm}
q Filling of coolant (air conditioner gas)

Using tool X3, fill the air conditioner circuit with
the coolant (air conditioner gas: R134a).
a Filling amount: 950 ± 50 g
(Per unit of air conditioner compressor)
a Two air compressors are used.
PC2000-8 5
Removal and installation of 3. Disconnect connectors CM01 (4) and CM02

monitor assembly 1
(5) from the rear of the monitor panel assembly
(2). [*1]
Removal a NC: Non-connected connector
lock position.
battery beforehand.
1. Remove panel (1).
2. Remove cover (3) from the rear of the monitor

panel assembly (2).
4. Remove monitor panel assembly (2).
Installation
removal.
[*1]
Care must be taken not to connect connector CM01
(4) and CM02 (5) for the monitor panel assembly to
non-connected connectors (NC) by error.
6 PC2000-8
Removal and installation of Installation

engine controller assembly 1
q Installation is done in the reverse order of
removal.
Removal
k Lower the work equipment completely to [*1]
the ground and stop the engine. q Make sure inside (particularly the bottom) of
k Set the work equipment lock lever to the the controller connector is free from sands,
lock position. dusts or water. If such foreign substances are
k Disconnect the negative (–) terminal of the present, clean them completely with the air
battery beforehand. blow. (Sands, dusts or water can cause defect
contact or allow commingling of water.)
1. Remove engine controller cover (1) from inside
the power container. a Reference
q Replacement procedure of O-ring seal on
power supply connector CE06 (5)
O-ring seal:
1010-074-0406 (Nihon-Deutsch Ltd.)
1) Remove cover (8) by pressing the claw

with tweezers [1].
2. Disconnect connectors CE05 (3), ENG (4) and

CE06 (5) from the engine controller assembly
(2). [*1]
a Connectors (3) and (4): Unlock using a
hexagonal 4-mm wrench.
3. Remove engine controller assembly (2).

a Remove the opposite side in the same 2) Remove O-ring (9) using tweezers [1].
procedures.
PC2000-8 7
Removal and installation of pump

controller assembly 1
Removal
lock position.
battery beforehand.
1. Open cover (1) from the rear of the operator's

cab.
2. Disconnect connectors (2) to (7).

a All the connectors: Unlock using the hex-
agonal 4-mm wrench.
3. Remove pump controller assemblies (8) and

(9).
Installation
removal.
8 PC2000-8
Removal and installation of VHMS Removal and installation of

controller assembly 1 Orbcomm terminal assembly for
Removal VHMS 1
k Lower the work equipment completely to Removal
the ground and stop the engine. k Lower the work equipment completely to
k Set the work equipment lock lever to the the ground and stop the engine.
lock position. k Set the work equipment lock lever to the
k Disconnect the negative (–) terminal of the lock position.
battery beforehand. k Disconnect the negative (–) terminal of the
battery beforehand.
1. Open distribution board cover from the cab
base. 1. Open distribution board cover from the cab
base.
2. Disconnect connectors CV03A (1), CV01 (2),
CV04A (3), CV02B (4), CV02A (5) and CV04B 2. Disconnect connector (1).
(6). [*1] a Turn the connector counterclockwise
while pressing it toward the controller.
3. Remove VHMS controller assembly (7).
3. Disconnect connector CK01 (2).
4. Remove VHMS Orbcomm terminal assembly

(4).
Installation
removal.
[*1] Installation
Care must be taken not to insert connectors CV03A q Carry out the installation in the reverse order of
(1) (white) and CV02A (5) (green) in reverse to removal.
wrong mating receptacles.
PC2000-8 9
SEN02141-00
© 2006 KOMATSU
All Rights Reserved
10
SEN01629-00
PC2000-8

PC2000-8 20001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic diagrams and drawings................................................................................................................... 3
Hydraulic circuit diagram...................................................................................................................... 3
PC2000-8 1
Hydraulic circuit diagram
Hydraulic diagrams and drawings PC2000-8
1
Hydraulic circuit diagram 1
SEN01629-00
PC2000-8 3
SEN01629-00
© 2006 KOMATSU
All Rights Reserved
6
SEN01630-01
PC2000-8

PC2000-8 20001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical diagrams and drawingss ................................................................................................................. 3
Electrical circuit diagram (1/2) .............................................................................................................. 3
Electrical circuit diagram (2/2) .............................................................................................................. 5
Connector arrangement diagram ......................................................................................................... 7
PC2000-8 1
Electrical circuit diagram (1/2)
Electrical diagrams and drawingss PC2000-8
SEN01630-01
PC2000-8 3
Electrical circuit diagram (2/2) PC2000-8
SEN01630-01
PC2000-8 5
Connector arrangement diagram
PC2000-8
Connector arrangement diagram
Connector Number Address of Connector Number Address of Connector Number Address of Connector Number Address of
Model Component name Model Component name Model Component name Model Component name
No. of pins stereogram No. of pins stereogram No. of pins stereogram No. of pins stereogram
815 HD36 14 Intermediate connector (Male) (connected to E01) AW-3 CV04A 070 14 VHMS controller AN-6 M84B DT 4 Triple pressure switch Z-6 RW4 4 Lower wiper brake relay S-1
A01 DRC 70 Intermediate connector AB-9, AL-9 CV04B 070 10 VHMS controller AN-6 N04 DT 12 Intermediate connector AC-2 RW5 5 Washer relay T-1
A02 DRC 70 Intermediate connector AB-9, AL-9 D01 SWP 8 Diode AC-1 N05 DT 8 Intermediate connector AC-1 S01 6 Starter switch Y-2
A03 DRC 70 Intermediate connector AB-9, AM-9 D02 SWP 8 Diode AC-2 N06 DT 12 Service connector W-2 S02 SWP 6 Light switch Q-8
A04 DRC 70 Intermediate connector AO-2 D03 SWP 8 Diode AC-2 N07 DT 12 Multilink S-9 S04 SWP 6 Swing lock switch Q-9
A05 DRC 40 Intermediate connector AO-2 D04 KES1 2 Diode AC-2 N09A/B DT 3 Intermediate connector S05 SWP 6 Machine push up switch P-9
A06 DRC 70 Intermediate connector A-1 D05 SWP 8 Diode AC-2 NE 3 Intermediate connector (Left bank) (Female) AW-2 S06 SWP 6 Boom shockless control switch P-9
A07 DT 6 Emergency stop switch BH-6 D06 8 Working lamp diode NE 2 Intermediate connector (Right bank) (Male) AW-2 S07 SWP 6 Beacon switch P-9
A08 DT 6 Emergency stop switch J-9 DA1 DT 2 Blower diode AB-5 NE 3 Engine position sensor AY-1 S10 090 3 Horn switch Q-7
A09 DRC 40 Intermediate connector L-1 DA2 DT 2 Blower diode AB-4 NEL 3 Intermediate connector (Left bank) (Male) AW-2 S11 090 3 Dump counter switch S-8
A10 DT 12 Intermediate connector AE-8 DA3 DT 2 Condenser diode AA-5 NER 2 Intermediate connector (Right bank) (Female) AW-2 S13 SWP 6 Step light switch Q-9
A11 DT 12 Intermediate connector AE-9 DA4 DT 2 Condenser diode AB-4 NF1 X 4 Service connector Z-7 S13A M 2 Service connector
A12 DT 12 Intermediate connector AE-8 DA5 DT 2 Compressor diode AA-4 OLLV DT 2 Engine oil level sensor AY-6 S14 M 3 PPC hydraulic lock switch R-8
A13 DT 12 Intermediate connector AE-8 DA6 DT 2 Compressor diode AB-4 P01 DT 3 Boom RAISE PPC pressure sensor AI-9 S15 SWP 6 Grease mode select switch P-9
A14 DT 12 Intermediate connector AE-4, AN-2 DW1 KES1 2 Wiper diode P-2 P02 DT 3 Bucket CURL PPC pressure sensor AI-9 S16 SWP 6 Room lamp switch P-8
A15 DT 6 Intermediate connector AN-3 DW2 KES1 2 Wiper diode P03 DT 3 Bucket DUMP PPC pressure sensor AI-9 S17 SWP 6 Sub lamp switch Q-8
A17 DT 4 Intermediate connector AE-4, AN-2 DW3 KES1 2 Washer diode P04 DT 3 Arm OUT PPC pressure sensor AH-9 S23A DT 3 Hydraulic tank strainer proximity switch H-1
A19 DT 2 Service connector (+12 V) E01 HD36 14 Intermediate connector (Female) (connected to 815) AW-3 P05 DT 3 Arm IN PPC pressure sensor AH-9 S23B DT 3 Hydraulic tank strainer proximity switch I-1
A20 DT 6 Intermediate connector M-9 ENBP DT 3 Blow-by pressure sensor AX-5 P06 DT 3 Left swing PPC pressure sensor AH-9 S24 DT 3 Ladder limit lamp M-4
A20A Air heater relay terminal A-2 ENG (L) DRC 60 Engine controller (Left bank) BA-8 P07 DT 3 Right swing PPC pressure sensor AG-8 S27A DT 2 Engine room lamp switch H-9
A20B Air heater relay terminal B-2 ENG (R) DRC 60 Engine controller (Right bank) AZ-1 P08 DT 3 Right swing PPC pressure sensor AG-8 S27B DT 2 Engine room lamp switch I-9
A21 DT 2 Intermediate connector G-9 F01 20 Fuse box AE-2 P09 X 2 Right travel (forward) PPC pressure switch AG-8 S28 DT 2 Pump room lamp switch BF-7
A22 DTP 4 Intermediate connector AO-1 G SUMITOMO 3 G sensor (Left bank) AY-5 P10 X 2 Right travel (reverse) PPC pressure switch AF-8 S29 DT 2 Cab base lamp switch AN-8
A23 DTP 4 Intermediate connector A-1 G SUMITOMO 3 G sensor (Right bank) BB-2 P11 X 2 Left travel (forward) PPC pressure switch AF-8 S30 DT 6 Step light switch B-6
A24 DTHD 1 Intermediate connector AP-2 GND P12 X 2 Left travel (reverse) PPC pressure switch AF-7 S30A DT 6 Maintenance light switch B-5
Terminal 1 GND (Engine controller) (Left bank) AZ-6
A24 DT 12 Intermediate connector E-1 CM850.L P13 X 2 Service valve PPC pressure switch S31 DT 2 Grease remain Hi level D-9
A25 DT 2 Intermediate connector AE-8 GND.R Terminal 1 GND (Engine controller) (Right bank) AY-1 P17 DT 2 Service connector S32 DT 3 Grease remain Lo level E-9
A27 DT 4 Intermediate connector AP-2 H01 DT 8 Intermediate connector Z-4 P19 DT 2 PTO oil temperature sensor BE-2 SR1 Terminal 1 Wiper relay terminal Z-1, AA-1
A29 DT 4 Intermediate connector (backup lamp) (OPT) M-2 H02 DT 12 Intermediate connector X-2 P20 M 3 Fuel control dial Q-7 SR1 Terminal 1 Wiper relay terminal AA-3, AB-2
A31 DT 8 Emergency stop prolix switch AC-3 H03 DT 8 Intermediate connector Z-4 P21A DT 2 Fuel level sensor C-3 SR2 Terminal 1 Wiper relay terminal Z-2, AA-1
A32 DT 6 Swing brake emergency drive switch AC-3 H04 DT 8 Intermediate connector Y-3 P21C DT 2 Fuel level (High) sensor C-6 SR2 Terminal 1 Wiper relay terminal AA-3, AB-2
A33 DT 12 Pump 1 emergency drive switch AC-4 H05 DT 20 Intermediate connector AB-7 P21D DT 2 Fuel level (Middle) sensor C-4 SR3 Terminal 1 Wiper relay terminal Z-2, AA-1
A34 DT 12 Pump 2 emergency drive switch AC-3 H06 DT 12 Intermediate connector AB-7 P21E DT 2 Fuel level (Low) sensor C-3 SR3 Terminal 1 Wiper relay terminal AA-3, AB-3
A35 DT 3 Bottom dump control valve L-1, AA-6 H07 DT 3 Intermediate connector W-9 P22 DT 2 Hydraulic oil temperature sensor J-1 SR4 Terminal 1 Wiper relay terminal Z-2, AB-1
ANR1 Terminal 1 Alternator R terminal BB-4 H11 090 2 Starter switch P-7 P23A DT 2 Air cleaner clogging sensor BC-6 SR4 Terminal 1 Wiper relay terminal AB-2, AB-3
ANR2 Terminal 1 Alternator R terminal BB-4 H14 DT 8 Intermediate connector Y-3 P23B DT 2 Air cleaner clogging sensor BC-6 ST1 DT 2 Stator motor BA-8
B01 DTHD 1 Intermediate connector AP-3 H15 DT 8 Intermediate connector X-3 P24 DT 2 Radiator coolant level sensor F-9 ST2 DT 2 Stator motor BA-8
B02 DTHD 1 Intermediate connector AP-3 J1939 DT 4 Intermediate connector AX-1 P25 AMP 3 VL1 pressure sensor G-1 SW1 Terminal 1 Emergency stop switch C1 terminal B-8, BH-8
B03 DTHD 1 Intermediate connector AP-3 JC01 6 Branch block (Left bank) AZ-9 P26 AMP 3 VL2 pressure sensor E-1 SW2 Terminal 1 Emergency stop switch N01 terminal A-9, BH-7
B04 DTHD 1 Intermediate connector AP-3 JC01 8 Branch block (Right bank) AY-1 P27 DT 4 J/S differential pressure sensor (VL1) AK-9 SW3 Terminal 1 Emergency stop switch NC1 terminal A-9, BG-7
B05 DTHD 1 Intermediate connector AP-3 JC02 6 Branch block (Left bank) BA-9 P28 DT 4 J/S differential pressure sensor (VL2) AJ-9 SW4 Terminal 1 Emergency stop switch C2 terminal A-8, BG-7
B11 Terminal 1 Circuit breaker M-9 JC02 6 Branch block (Right bank) AY-1 P29 DT 2 Air temperature sensor AK-1 T01 Terminal 1 Cab GND W-2
B12A Terminal 1 Circuit breaker M-9 JC03 9 Branch block (Left bank) BA-9 P32 AMP 3 VR1 pressure sensor C-6 T01 Terminal 1 Battery (Left) GND A-2
B12B Terminal 1 Circuit breaker M-9 K01 3 Resistor P33 AMP 3 VR2 pressure sensor C-7 T02 Radio body GND W-9
B13 Terminal 1 Circuit breaker M-9 K01A DT 3 Pump 1 emergency drive resistance P34 AMP 3 Fan pump pressure sensor (O/C) BH-4 T02 Terminal 1 Battery (Left) GND A-2
B14A Terminal 1 Circuit breaker M-9 K01A M 2 Pump 1 emergency drive resistance AN-4 P35 AMP 3 Fan pump pressure sensor (RAD) BF-2 T03 Terminal 1 Battery (Left) GND M-4
B14B Terminal 1 Circuit breaker M-9 K01B M 2 Pump 2 emergency drive resistance AN-4 P36 DT 4 J/S differential pressure sensor (VR1) F-1 T06 Terminal 1 Radio body GND V-9
B15A Terminal 1 Circuit breaker N-9 L.P 14 Intermediate connector (Male) AW-3 P37 DT 4 J/S differential pressure sensor (VR2) D-1 T10A Terminal 1 Cab base GND AI-1
B15B Terminal 1 Circuit breaker M-9 L.S 14 Intermediate connector (Female) AW-3 P38 DT 2 Hydraulic oil low temperature sensor I-1 T10B Terminal 1 Cab base GND AJ-1
B16A Terminal 1 Circuit breaker N-9 L01A DT 2 Boom working lamp, upper right P39 DT 2 Hydraulic oil level sensor K-1 T11 Terminal 1 Cab base GND AI-1
B16B Terminal 1 Circuit breaker M-9 L01B DT 2 Boom working lamp, upper left P40 DT 2 Hydraulic oil filter clogging sensor I-1 T12 Terminal 1 Cab base GND AJ-1
B17 Terminal 1 Circuit breaker M-9 L01C DT 2 Boom working lamp, lower right P41A DT 3 Intermediate connector (Exhaust temperature sensor) BC-3, BC-4 T14 Terminal 1 Revolving frame GND M-3
B18 Terminal 1 Circuit breaker M-8 L01D DT 2 Boom working lamp, lower left P41B DT 3 Intermediate connector (Exhaust temperature sensor) BC-3, BC-4 TAMB PACKARD 2 Air temperature sensor BA-9
B21A Terminal 1 Circuit breaker AO-8 L02A DT 2 Fuel tank upper headlamp C-5 P41C DT 3 Intermediate connector (Exhaust temperature sensor) BC-3 TB01 Terminal 1 Cab base GND AP-1
B21B Terminal 1 Circuit breaker AO-8 L02B DT 2 Fuel tank upper downlamp C-4 P41D DT 3 Intermediate connector (Exhaust temperature sensor) BC-3, BD-2 TB02 Terminal 1 Cab base GND AP-1
B21C Terminal 1 Circuit breaker AO-8 L03 M 2 Cab lamp AQ-8 P45 DT 3 Wiper proximity switch AQ-7 TB03 Terminal 1 Cab base GND AP-2
B22A Terminal 1 Circuit breaker AO-9 L04A DT 2 Headlamp AF-6 P48 DT 3 Grease pump discharge pressure sensor D-9 TB04 Terminal 1 Cab base GND AP-2
B22B Terminal 1 Circuit breaker AO-9 L04B DT 2 Headlamp AF-3 PAMB AMP 3 Ambient pressure sensor AW-4 TB05 Terminal 1 Cab base GND AP-1
B22C Terminal 1 Circuit breaker AO-9 L04C DT 2 Headlamp AF-7 PCV1 SUMITOMO 2 Fuel pump #1 (Left bank) AZ-6 TB12 Terminal 1 GND AN-7
B23A Terminal 1 Circuit breaker AO-9 L04D DT 2 Headlamp AF-4 PCV1 SUMITOMO 2 Fuel pump #1 (Right bank) BB-2 TB13 Terminal 1 GND AC-8
B23B Terminal 1 Circuit breaker AO-9 L05A DT 2 Beacon lamp AU-9 PCV2 SUMITOMO 2 Fuel pump #2 (Left bank) AX-6 TB14 Terminal 1 GND AC-8
B24A Terminal 1 Circuit breaker AO-9 L05B DT 2 Intermediate connector J-9 PCV2 SUMITOMO 2 Fuel pump #2 (Right bank) BB-2 TB15 Terminal 1 GND AD-9
B24B Terminal 1 Circuit breaker AO-9 L05C DT 2 Beacon lamp (OPT) J-9 PFUEL AMP 3 Common rail pressure sensor (Left bank) BA-7 TB16 Terminal 1 GND AD-9
B25A Terminal 1 Circuit breaker AP-9 L06 DT 2 Step lamp AV-8 PFUEL AMP 3 Common rail pressure sensor (Right bank) BA-1 TE01 Terminal 1 GND BE-2
B25B Terminal 1 Circuit breaker AP-9 L06B DT 2 Step and ladder lamps M-5 PIM SUMITOMO 3 Boost pressure sensor BA-9 TE02 Terminal 1 GND BH-6
B26A Terminal 1 Circuit breaker AO-8 L07 DT 2 Flash lamp AF-2 POIL FRAMATOME 4 Oil pressure sensor BA-7 TE04 Terminal 1 GND BC-2
B26B Terminal 1 Circuit breaker AO-8 L08A DT 2 Engine room lamp G-9 R.P 14 Intermediate connector (Male) AX-1 TE05 Terminal 1 GND BD-2
B27A Terminal 1 Circuit breaker AO-7 L08B DT 2 Engine room lamp L-8 R.S 14 Intermediate connector (Female) AX-1 TE06 Terminal 1 GND BD-2
B27B Terminal 1 Circuit breaker AO-7 L10 DT 2 Cab base lamp AN-8 R01A Terminal 1 Battery relay (Right) E terminal M-7 TE07 Terminal 1 GND BE-2
B28A Terminal 1 Circuit breaker AP-7 L11 DT 2 Side lamp (Cab base) AN-5 R01B Terminal 1 Battery relay (Left) E terminal M-7 TE08 Terminal 1 GND BE-2
B28B Terminal 1 Circuit breaker AP-7 L12 DT 2 Fuel tank upper-right downlamp C-5 R02A Terminal 1 Battery relay (Right) BR terminal M-7 TFUEL PACKARD 2 Fuel temperature sensor (Left bank) AW-7
B28C Terminal 1 Circuit breaker AP-7 L13 DT 2 Pump room lamp BE-8 R02B Terminal 1 Battery relay (Left) BR terminal N-7 TFUEL PACKARD 2 Fuel temperature sensor (Right bank) BB-3
B29A Terminal 1 Circuit breaker AP-8 L14 DT 2 Left skew lamp (Cab base) AH-1 R03A Terminal 1 Battery relay (Right) M terminal M-8 TIM PACKARD 2 Air intake manifold temperature sensor BA-9
B29B Terminal 1 Circuit breaker AP-8 L20 090 2 Emergency stop lamp O-7 R03B Terminal 1 Battery relay (Left) M terminal M-7 TM1 Terminal 1 GND J-9
B30A Terminal 1 Circuit breaker AP-8 L21 090 2 Ladder warning lamp O-9 R03C Terminal 1 Battery relay (Right) M terminal M-8 TOIL PACKARD 2 Engine oil temperature sensor BA-7
B30B Terminal 1 Circuit breaker AP-8 L22 090 2 Automatic grease warning lamp O-9 R03D Terminal 1 Battery relay (Left) M terminal M-7 TR1 Terminal 1 GND (Revolving frame) K-1
C10 DT 3 Model selection pump controller Z-8 L23 090 2 Fan reverse rotation warning lamp P-7 R04B Terminal 1 Battery relay (Left) B terminal M-8 TR2 Terminal 1 GND (Revolving frame) K-1
C11 DT 3 Model selection pump controller Z-6 L25 090 2 Strainer warning lamp O-8 R05 5 PPC lock starter cut relay AC-4 TR3 Terminal 1 GND (Revolving frame) K-1
CE02 DRC 50 Engine controller (Left bank) BC-5 L26 090 2 Emergency prolix warning lamp O-8 R06 5 Hydraulic oil strainer off stating cut relay AC-4 TS1 Terminal 1 GND B-8, BG-8
CE03 DTP 4 Engine controller (Left bank) BC-5 M01 PA 9 Radio V-9 R07 5 Step lamp relay AD-5 TW1 Terminal 1 GND AR-8
CE05 DRC 50 Engine controller (Right bank) BG-6 M02 M 2 Speaker (Left) AV-8 R08 6 Work lamp relay AE-2 TW2 Terminal 1 GND AR-1
CE06 DTP 4 Engine controller (Right bank) BG-6 M03 M 2 Speaker (Right) AT-9 R09 6 Side rear lamp relay AE-3 TWTR PACKARD 2 Coolant sensor BA-1
CK01 DRC 40 ORBCOM controller AN-3 M04 DT 2 Cigarette lighter U-9 R10 6 Right work lamp relay AE-3 V01 DT 2 Variable back pressure A-3
CM01 070 18 Monitor P-6 M05A DT 6 Upper wiper motor AS-8 R11 6 Left work lamp relay AE-3 V02 DT 2 Swing priority A-3
CM02 070 12 Monitor P-5 M05B DT 6 Lower wiper motor AR-1 R12 5 Swing parking brake relay AD-5 V03 DT 2 Main 2-stage relief valve A-3
CM05 IRA-A20 8 Rear camera (OPT) M06A KES 2 Window washer AM-1 R13 5 Flash light relay AD-4 V04 DT 2 Arm throttle valve (Left) A-3
CM850.L Terminal 1 GND (Engine controller) (Left bank) BA-8 M06B KES 2 Window washer AL-1 R14 6 Horn relay AE-3 V05 DT 2 Arm throttle valve (Right) A-4
CM850.R Terminal 1 GND (Engine controller) (Right bank) AZ-1 M07A YAZAKI 2 Horn (Treble tone) AG-1 R15A Terminal 1 Intake air heater relay N-8 V06 DT 2 Boom throttle valve A-4
CN.ANR DT 2 Intermediate connector AX-1 M07B YAZAKI 2 Horn (Treble tone) AF-5 R15B Terminal 1 Intake air heater relay N-8 V07 DT 2 Travel straight A-4
CN1 2 Injector #1 (Left bank) AZ-5 M08A YAZAKI 2 Horn (Bass tone) AF-2 R15C Terminal 1 Intake air heater relay N-8 V08 DT 2 2-stage safety valve boom head A-4
CN1 2 Injector #1 (Right bank) BB-3 M08B YAZAKI 2 Horn (Bass tone) AF-6 R16A Terminal 1 Intake air heater relay N-9 V09 DT 2 Boom shockless control valve AE-7
CN2 2 Injector #2 (Left bank) AZ-5 M10 DT 2 Service connector (+24 V) R16B Terminal 1 Intake air heater relay N-9 V10 DT 2 Boom shockless control valve AD-7
CN2 2 Injector #2 (Right bank) BB-3 M11 M 4 DC/DC converter AD-1 R16C Terminal 1 Intake air heater relay N-8 V11 DT 2 No. 1 main pump EPC solenoid BH-5
CN3 2 Injector #3 (Left bank) AY-5 M12 DT 2 Service connector (+12 V) V-1 R17 5 Pre heater relay AD-5 V12 DT 2 No. 1 main pump EPC solenoid BH-4
CN3 2 Injector #3 (Right bank) BB-2 M14 DT 2 Travel alarm buzzer M-2 R20 5 Beacon relay AC-4 V13 DT 2 No. 2 main pump EPC solenoid BH-5
CN4 2 Injector #4 (Left bank) AY-5 M16 KES 2 Truck counter buzzer P-4 R30A 5 Blower relay AB-6 V14 DT 2 No. 2 main pump EPC solenoid BH-5
CN4 2 Injector #4 (Right bank) BA-2 M27A YAZAKI 18 Air conditioner unit (Upper) Y-9 R30B 5 Blower relay AB-6 V15 DT 2 Fan pump BG-2
CN5 2 Injector #5 (Left bank) AX-5 M27B YAZAKI 18 Air conditioner unit (Lower) Y-9 R31A 4 Compressor relay AA-6 V16 DT 2 Fan pump BG-2
CN5 2 Injector #5 (Right bank) AY-5 M29A AMP 20 AC control panel T-9 R31B 4 Compressor relay AB-6 V17 DT 2 Fan pump reverse solenoid (O/C) BH-4
CN6 2 Injector #6 (Left bank) AX-4 M29B AMP 20 AC control panel T-9 R32A 5 Condenser relay AA-6 V18 DT 2 Fan pump reverse solenoid (RAD) H-9
CN6 2 Injector #6 (Right bank) AX-4 M30A AMP 16 AC control panel U-9 R32B 5 Condenser relay AA-5 V19 DT 2 Bucket high cancel solenoid E-1
CP01 DRC 24 Pump controller 1 Z-8 M30B AMP 16 AC control panel T-9 R33A 5 Condenser relay (Hi) AA-6 V20 DT 2 Swing parking brake G-1
CP02 DRC 40 Pump controller 1 Z-7 M33A SUMITOMO 4 Air conditioner unit (Upper) Z-9 R33B 5 Condenser relay (Hi) AA-5 V21A DT 2 PPC hydraulic lock valve AD-7
CP03 DRC 40 Pump controller 1 Z-7 M33B SUMITOMO 4 Air conditioner unit (Lower) Y-9 RES 2 Pull up resistor (Right bank) BA-1 V21B DT 2 PPC hydraulic lock valve AD-7
CP04 DRC 24 Pump controller 2 Z-5 M34 X 1 A/C compressor electromagnetic clutch I-9 RES1 2 Pull up resistor (Left bank) BA-8 V25 DT 2 Grease pump solenoid E-9
CP05 DRC 40 Pump controller 2 Z-5 M35 X 1 A/C compressor electromagnetic clutch H-9 RES2 3 Resistor (Left bank) AW-2 V30 DT 2 OPT connector
CP06 DRC 40 Pump controller 2 Z-5 M36 DT 3 Condenser J-1 RES3 3 Resistor (Left bank) AW-2 VH16 DT 2 Exhaust temperature sensor (LF) BC-7
CV01 070 20 VHMS controller AN-4 M36 DT 2 Air suspension seat R-8 REV 2 Connector AW-3 VH17 DT 2 Exhaust temperature sensor (LR) BD-7
CV02A 070 18 VHMS controller AN-5 M37 DT 3 Condenser J-1 RW1 4 Upper wiper relay Q-1 VH18 DT 2 Exhaust temperature sensor (RF) BD-8
CV02B 070 12 VHMS controller AN-6 M79 M 2 Socket V-9 RW2 4 Upper wiper brake relay P-1 VH19 DT 2 Exhaust temperature sensor (RR) BD-8
CV03A 070 18 VHMS controller AN-5 M84A DT 4 Triple pressure switch Z-8 RW3 4 Lower wiper relay S-1
SEN01630-01
PC2000-8
7
SEN01630-01
© 2006 KOMATSU
All Rights Reserved
10

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SEN01607-02

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual................................................................................................................ 2

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN01607-02

00 Index and foreword SEN01608-02

10 Structure, function and maintenance standard SEN01613-00

20 Standard value table SEN01624-00

30 Testing and adjusting SEN01625-00

Troubleshooting by failure code, Part 5 SEN02100-00 Q

50 Disassembly and assembly SEN01627-00

90 Diagrams and drawings SEN01628-01

Foreword and general information SEN01610-01

10 Structure, function and maintenance standard

Hydraulic system, Part 1 SEN01618-00

20 Standard value table

30 Testing and adjusting

Testing and adjusting, Part 3 SEN02009-00

Failure code [CA132] Throttle Sensor Low Error..................................................................... 44

Failure code [CB452] Rail Press Sensor Low Error ................................................................ 8

Failure code [DBB0KQ] VHMS Connector Mismatch

Troubleshooting by failure code, Part 6 SEN02101-00

Failure code [f@BZNR] Very High RBR CYL Exhaust Temp

50 Disassembly and assembly

Power train SEN02136-00

Removal and installation of pump controller assembly ........................................................... 8

90 Diagrams and drawings

PC2000-8 Hydraulic excavator

Form No. SEN01609-02

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Safety notice 1 (Rev. 2006/09)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-