Professional Documents
Culture Documents
Shop Manual Pc2000-8
Shop Manual Pc2000-8
HYDRAULIC PC2000 -8
EXCAVATOR
SERIAL NUMBERS 20001 and up
SEN01609-22
PC2000-8
PC2000-8 1
SEN01609-22 00 Index and foreword
01 Specification SEN01611-04
Specification and technical data SEN01612-04
40 Troubleshooting SEN01626-05
Failure code table and fuse locations SEN02011-02
General information on troubleshooting SEN02012-05
Troubleshooting by failure code, Part 1 SEN02096-03
Troubleshooting by failure code, Part 2 SEN02097-02
Troubleshooting by failure code, Part 3 SEN02098-02
Troubleshooting by failure code, Part 4 SEN02099-03
2 PC2000-8
00 Index and foreword SEN01609-22
PC2000-8 3
SEN01609-22 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN01609-22
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN01610-04
Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
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 SEN01612-04
Specification drawings ............................................................................................................. 2
Specifications........................................................................................................................... 6
Weight table ............................................................................................................................. 10
Table of fuel, coolant and lubricants ........................................................................................ 16
4 PC2000-8
00 Index and foreword SEN01609-22
PC2000-8 5
SEN01609-22 00 Index and foreword
6 PC2000-8
00 Index and foreword SEN01609-22
40 Troubleshooting
Failure code table and fuse locations SEN02011-02
Failure code table .................................................................................................................... 2
Before carrying out troubleshooting of electrical system ......................................................... 9
General information on troubleshooting SEN02012-05
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- branch box and T- branch adapter table ............................................................................. 45
Troubleshooting by failure code, Part 1 SEN02096-03
Failure code [0410KA] Fuel LV. Sensor Failure....................................................................... 4
Failure code [0410KB] Fuel LV. Sensor Failure....................................................................... 6
Failure code [6014NX] Hydraulic Oil Filter Clogging
(or change of VHMS-LED display from n5 to 51) ............................................................. 8
Failure code [8800ZG] Auto grease abnormally...................................................................... 9
Failure code [7@HAZL] VR1/P1F Relief Press Abnormality ................................................... 10
Failure code [7@HBZL] VL1/P1R Relief Press Abnormality ................................................... 11
Failure code [7@HCZL] VR2/P2F Relief Press Abnormality................................................... 12
Failure code [7@HDZL] VL2/P2R Relief Press Abnormality ................................................... 14
Failure code [AA10NX] Aircleaner Clogging............................................................................ 16
Failure code [AB00KE] Charge Voltage Low ........................................................................... 18
Failure code [aB00KE] Low Upper ALR Charge Voltage
(or change of VHMS-LED display from n9 to 11) ............................................................. 20
Failure code [B@BAZG] Eng. Oil Press. Low ......................................................................... 22
Failure code [B@BAZK] Eng. Oil Level Low ........................................................................... 24
Failure code [B@BCNS] Eng. Water Overheat ....................................................................... 26
Failure code [B@BCZK] Eng. Water Lvl Low .......................................................................... 28
Failure code [B@CBNS] PTO Oil Overheat
(or change of VHMS-LED display from n5 to 61) ............................................................. 30
Failure code [B@HANS] Hydr. Oil Overheat ........................................................................... 32
Failure code [B@HAZK] Low Hydraulic Oil Level
(or change of VHMS-LED display from n5 to 52) ............................................................. 34
Failure code [CA111] ECM Critical Internal Failure ................................................................. 36
Failure code [CB111] ECM Critical Internal Failure ................................................................. 38
Failure code [CA115] Eng. Ne and Bkup Speed Sens Error ................................................... 40
Failure code [CB115] Eng. Ne and Bkup Speed Sens Error ................................................... 41
Failure code [CA122] Chg Air Press Sensor High Error.......................................................... 42
Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 44
Failure code [CA131] Throttle Sensor High Error .................................................................... 46
Failure code [CA132] Throttle Sensor Low Error..................................................................... 48
Failure code [CA135] Eng Oil Press Sensor High Error .......................................................... 50
Failure code [CA141] Eng Oil Press Sensor Low Error........................................................... 52
Failure code [CA144] Coolant Temp Sens High Error ............................................................. 54
Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 56
Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 58
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Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 60
Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 62
Failure code [CB187] Sens Supply 2 Volt Low Error ............................................................... 62
Failure code [CA212] Eng Oil Temp Sensor High Error........................................................... 64
Failure code [CA213] Eng Oil Temp Sensor Low Error ........................................................... 66
Troubleshooting by failure code, Part 2 SEN02097-02
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/B#1) Open/Short Error ............................................................. 38
Failure code [CA323] Inj #5(L/B#5) Open/Short Error ............................................................. 40
Failure code [CA324] Inj #3(L/B#3) Open/Short Error ............................................................. 42
Failure code [CA325] Inj #6(L/B#6) Open/Short Error ............................................................. 44
Failure code [CA331] Inj #2(L/B#2) Open/Short Error ............................................................. 46
Failure code [CA332] Inj #4(L/B#4) Open/Short Error ............................................................. 48
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
Troubleshooting by failure code, Part 3 SEN02098-02
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
8 PC2000-8
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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 [CA1257] Harness Key Error .............................................................................. 38
Failure code [CB1257] Harness Key Error .............................................................................. 39
Failure code [CB1548] Inj #7(R/B#1) Open/Short Error .......................................................... 40
Failure code [CB1549] Inj #8(R/B#2) Open/Short Error .......................................................... 42
Failure code [CB1551] Inj #10(R/B#4) Open/Short Error ........................................................ 44
Failure code [CB1552] Inj #11(R/B#5) Open/Short Error ........................................................ 46
Failure code [CB1553] Inj #12(R/B#6) Open/Short Error ........................................................ 48
Failure code [CB1622] Inj #9(R/B#3) Open/Short Error .......................................................... 50
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
Troubleshooting by failure code, Part 4 SEN02099-03
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 [DAFRMC] CAN Discon (Monitor Detected) ....................................................... 38
Failure code [DA2TMC] Pump Comm. ECM Child Abnormality .............................................. 40
Failure code [DBB0KK] VHMS Source Voltage Error
(or change of VHMS-LED display from n9 to 01) ............................................................. 42
Failure code [DBB0KQ] VHMS Connector Mismatch
(or change of VHMS-LED display from nF to 11) ............................................................. 44
Failure code [DBB5KP] VHMS 5V source sys Error
(or change of VHMS-LED display from n9 to 04) ............................................................. 46
Failure code [DBB6KP] VHMS 24V source sys Error
(or change of VHMS-LED display from n9 to 02) ............................................................. 48
Failure code [DBBQKR] KOM-NET/c error
(or change of VHMS-LED display from n8 to 02) ............................................................. 50
Failure code [DGE5KX] Ambient Air Temp Sensor Failure
(or change of VHMS-LED display from n4 to 01) ............................................................. 52
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C .............................................................. 54
PC2000-8 9
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10 PC2000-8
00 Index and foreword SEN01609-22
PC2000-8 11
SEN01609-22 00 Index and foreword
12 PC2000-8
00 Index and foreword SEN01609-22
PC2000-8 13
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14 PC2000-8
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PC2000-8 15
SEN01609-22
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 11-17 (01)
16
SEN01610-04
PC2000-8
PC2000-8 1
SEN01610-04 00 Index and foreword
Safety notice 1
(Rev. 2008/08)
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.
2 PC2000-8
00 Index and foreword SEN01610-04
PC2000-8 3
SEN01610-04 00 Index and foreword
4 PC2000-8
00 Index and foreword SEN01610-04
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
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
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
SEN01610-04 00 Index and foreword
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
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,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 PC2000-8
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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.
01. Specification
This section explains the specifications of the machine.
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.
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.
PC2000-8 7
SEN01610-04 00 Index and foreword
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
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.
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.
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
00 Index and foreword SEN01610-04
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
PC2000-8 9
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10 PC2000-8
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PC2000-8 11
SEN01610-04 00 Index and foreword
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.
12 PC2000-8
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PC2000-8 13
SEN01610-04 00 Index and foreword
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
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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
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16 PC2000-8
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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.
PC2000-8 17
SEN01610-04 00 Index and foreword
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.
18 PC2000-8
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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
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20 PC2000-8
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q 114 engine
q 107 engine
PC2000-8 21
SEN01610-04 00 Index and foreword
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (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)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 PC2000-8
00 Index and foreword SEN01610-04
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.
(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)
automobile Insulator Soft polyvinyl chloride
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
SEN01610-04 00 Index and foreword
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
24 PC2000-8
00 Index and foreword SEN01610-04
(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.
(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
SEN01610-04 00 Index and foreword
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
00 Index and foreword SEN01610-04
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.
PC2000-8 27
SEN01610-04 00 Index and foreword
28 PC2000-8
00 Index and foreword SEN01610-04
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
SEN01610-04 00 Index and foreword
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
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30 PC2000-8
00 Index and foreword SEN01610-04
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
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-
onal portion at the male end. (Fig. 13)
PC2000-8 31
SEN01610-04 00 Index and foreword
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 PC2000-8
00 Index and foreword SEN01610-04
PC2000-8 33
SEN01610-04 00 Index and foreword
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.
7. 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 — —
34 PC2000-8
00 Index and foreword SEN01610-04
8. 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.
9. 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.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
PC2000-8 35
SEN01610-04 00 Index and foreword
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
36 PC2000-8
00 Index and foreword SEN01610-04
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
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
SEN01610-04 00 Index and foreword
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
00 Index and foreword SEN01610-04
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
SEN01610-04 00 Index and foreword
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
40 PC2000-8
00 Index and foreword SEN01610-04
PC2000-8 41
SEN01610-04
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
42
SEN01612-04
PC2000-8
01 Specification 1
Specification and technical data
Specification drawings .................................................................................................................................... 2
Specifications .................................................................................................................................................. 6
Weight table .................................................................................................................................................. 10
Table of fuel, coolant and lubricants.............................................................................................................. 16
PC2000-8 1
SEN01612-04 01 Specification
Specification drawings 1
Backhoe specification 1
2 PC2000-8
01 Specification SEN01612-04
PC2000-8 3
SEN01612-04 01 Specification
4 PC2000-8
01 Specification SEN01612-04
PC2000-8 5
SEN01612-04 01 Specification
Specifications 1
Backhoe specification
6 PC2000-8
01 Specification SEN01612-04
PC2000-8 7
SEN01612-04 01 Specification
8 PC2000-8
01 Specification SEN01612-04
PC2000-8 9
SEN01612-04 01 Specification
Weight table 1
k This weight table is a guide for use when transporting or handling components.
Backhoe specification
Unit: kg
Machine model PC2000-8
Serial number 20001 and up
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
10 PC2000-8
01 Specification SEN01612-04
Unit: kg
Machine model PC2000-8
Serial number 20001 and up
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 hydraulic ladder) 1,797
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 11
SEN01612-04 01 Specification
Unit: kg
Machine model PC2000-8
Serial number 20001 and up
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
12 PC2000-8
01 Specification SEN01612-04
k This weight table is a guide for use when transporting or handling components.
PC2000-8 13
SEN01612-04 01 Specification
Unit: kg
Machine model PC2000-8
Serial number 20001 and up
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
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 136
Bucket line 93
Bottom dump line 26
Travel line 91
Straight travel line 11
Swing line 49
Solenoid valve 31
Solenoid valve line 8
Shuttle valve line 51
PPC control line 8
PPC main line 38
PPC delivery line 26
PPC bottom dump line 10
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
14 PC2000-8
01 Specification SEN01612-04
Unit: kg
Machine model PC2000-8
Serial number 20001 and up
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 assembly (Excluding piping) 13,200
Arm assembly (Excluding piping) 6,850
Bucket assembly 14,315
Boom cylinder assembly 2,330 × 2
Arm cylinder assembly 1,100 × 2
Bucket cylinder assembly 1,496 × 2
Bottom dump cylinder assembly 309 × 2
Front and rear bucket connecting pin 41 × 2
Bottom dump cylinder rod pin 41 × 2
Bottom dump cylinder bottom pin 26 × 2
Boom top pin 99 × 2
Boom foot pin 110 × 2
Boom cylinder rod pin 61 × 2
Boom cylinder bottom pin 87 × 2
Arm top pin 106 × 2
Arm cylinder rod pin 28 × 2
Arm cylinder bottom pin 28 × 2
Bucket cylinder rod pin 51 × 2
Bucket cylinder bottom pin 68 × 2
PC2000-8 15
SEN01612-04 01 Specification
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
16 PC2000-8
01 Specification SEN01612-04
PC2000-8 17
SEN01612-04
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 08-17 (01)
18
SEN01614-01
PC2000-8
PC2000-8 1
SEN01614-01 10 Structure, function and maintenance standard
2 PC2000-8
10 Structure, function and maintenance standard SEN01614-01
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
SEN01614-01 10 Structure, function and maintenance standard
PTO
4 PC2000-8
10 Structure, function and maintenance standard SEN01614-01
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
SEN01614-01 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01614-01
PC2000-8 7
SEN01614-01
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 08-11
8
SEN01615-01
PC2000-8
PC2000-8 1
SEN01615-01 10 Structure, function and maintenance standard
Power train
2 PC2000-8
10 Structure, function and maintenance standard SEN01615-01
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
SEN01615-01 10 Structure, function and maintenance standard
Swing machinery
4 PC2000-8
10 Structure, function and maintenance standard SEN01615-01
Specification
Reduction ratio: (35 + 190)/35 × (17 + 83)/17 = 37.815
Unit: mm
No. Check Item Criteria Remedy
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
Backlash between No. 1
20 planetary carrier and No. 2 sun 0.41 – 0.72 —
gear
Backlash between No. 2 sun Replace
21 0.15 – 0.38 —
gear and No. 2 planetary gear
Backlash between No. 2 plane-
22 0.23 – 0.67 —
tary gear and ring gear
Backlash between No. 2
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
SEN01615-01 10 Structure, function and maintenance standard
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
No. Check Item Criteria Remedy
Clearance of bearing in axial Standard clearance Clearance limit
5 direction (when mounted on Replace
0.5 – 1.5 2.0
machine)
Specifications
Reduction ratio: 131/16 = 8.1875
Amount of grease: 80 l (G2-LI)
6 PC2000-8
10 Structure, function and maintenance standard SEN01615-01
PC2000-8 7
SEN01615-01 10 Structure, function and maintenance standard
Final drive
8 PC2000-8
10 Structure, function and maintenance standard SEN01615-01
Unit: mm
No. Check Item Criteria Remedy
Backlash between drive gear Standard clearance Clearance limit
19
and driven gear 0.21 – 0.73 —
Backlash between No. 1 sun
20 0.085 – 0.207 —
gear and driven gear
Backlash between No. 1 sun
21 0.25 – 0.46 —
gear and No. 1 planetary gear
Backlash between No. 1 sun
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
SEN01615-01 10 Structure, function and maintenance standard
Sprocket
Unit: mm
No. Check Item Criteria Remedy
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
10 Structure, function and maintenance standard SEN01615-01
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
SEN01615-01
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 08-11
12
SEN01616-01
PC2000-8
PC2000-8 1
SEN01616-01 10 Structure, function and maintenance standard
Track frame 1
2 PC2000-8
10 Structure, function and maintenance standard SEN01616-01
PC2000-8 3
SEN01616-01 10 Structure, function and maintenance standard
Idler 1
4 PC2000-8
10 Structure, function and maintenance standard SEN01616-01
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
SEN01616-01 10 Structure, function and maintenance standard
Carrier roller 1
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
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 —
Standard Tolerance Standard Clearance
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
10 Structure, function and maintenance standard SEN01616-01
Track roller 1
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
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 —
Standard Tolerance Standard Clearance
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
SEN01616-01 10 Structure, function and maintenance standard
Track shoe 1
8 PC2000-8
10 Structure, function and maintenance standard SEN01616-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
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
PC2000-8 9
SEN01616-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
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
10 PC2000-8
10 Structure, function and maintenance standard SEN01616-01
Double shoe
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
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
SEN01616-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
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
10 Structure, function and maintenance standard SEN01616-01
HIC system 1
a HIC: Abbreviation for Hydraulic Idler Cushion
Serial No.: 20001 – 20197
Operation
q The space between yoke (2) and plunger (3) is
filled with grease. The space between plunger (4)
and cylinder (5) is filled with hydraulic oil at the
constant pressure of 17.7 MPa {180 kg/cm2}.
This hydraulic oil is connected through relief-
check valve (7) to accumulator (8).
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).
q If idler (1) returns forward, the oil is returned by
the gas pressure in the accumulator through
the check valve of the relief-check valve to cyl-
inder (5). The cushion force decreases and the
system returns to the original condition accord-
ing to the forward movement of the idler.
PC2000-8 13
SEN01616-01 10 Structure, function and maintenance standard
14 PC2000-8
10 Structure, function and maintenance standard SEN01616-01
1. Idler
2. Accumulator
3. Center swivel joint
4. Valve
5. Yoke
6. Plunger
7. Cushion cylinder
7a. Plunger
7b. Plug
8. Check valve
9. Pressure reducing valve
10. Check valve block
11. Air bleeding plug
12. Plug
13. Check valve
14. Relief valve with check valve
15. Safety valve
16. Drain valve
PC2000-8 15
SEN01616-01 10 Structure, function and maintenance standard
System diagram
Serial No.: 20198 and up
Operation
q Oil is charged to the HIC circuit from the for- q Since the forward circuit of right travel motor
ward circuit of right travel motor (5) through (5) is kept connected to the HIC circuit, the
check valve (6) and pressure reducing valve pressure in the HIC circuit is maintained at
(7). 17.7 MPa {180 kg/cm2}.
q The oil from the right travel motor is pressure- q Yoke (18) has the role of a grease cylinder and
reduced by pressure reducing valve (7) and the space to plunger (17) is filled with grease.
filled in cushion cylinder (16) to extend plunger q When an external force is applied to idler (20)
(16a) to the stroke end. to move it back, plunger (16a) of cushion cylin-
q The oil is filled in accumulator (10) until nitro- der (16) is pushed in and the pressure in cush-
gen gas pressure (13.2 MPa {135 kg/cm2}) in it ion cylinder (16) increases.
reaches the set pressure (17.7 MPa {180 kg/ q If the pressure in cushion cylinder (16)
cm2}) of pressure reducing valve (7). increases above the cracking pressure of relief
q If the HIC circuit pressure lowers below the set valve with check valve (13), the relief valve
pressure (17.7 MPa {180 kg/cm2}) because of opens and the oil flows to accumulator (10).
leakage from accumulator (10), etc., oil is q The actual cracking pressure of relief valve
added when the forward travel pressure of the with check valve (13) is 25.7 MPa {262 kg/
right travel motor rises above 17.7 MPa {180 cm2}. (Because, the cracking pressure of the
kg/cm2}. relief valve when the back pressure is 0 MPa
{0 kg/cm2} + set pressure of pressure reducing
valve (7) = 25.7 MPa {262 kg/cm2}).
16 PC2000-8
10 Structure, function and maintenance standard SEN01616-01
PC2000-8 17
SEN01616-01 10 Structure, function and maintenance standard
1. Valve
2. Body
3. Bladder
4. Check valve
Specification
18 PC2000-8
10 Structure, function and maintenance standard SEN01616-01
PC2000-8 19
SEN01616-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
20
SEN01618-05
PC2000-8
PC2000-8 1
SEN01618-05 10 Structure, function and maintenance standard
2 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
PC2000-8 3
SEN01618-05 10 Structure, function and maintenance standard
4 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
PC2000-8 5
SEN01618-05 10 Structure, function and maintenance standard
6 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
PC2000-8 7
SEN01618-05 10 Structure, function and maintenance standard
Hydraulic tank 1
8 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
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}
PC2000-8 9
SEN01618-05 10 Structure, function and maintenance standard
Oil cooler 1
10 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
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 11
SEN01618-05 10 Structure, function and maintenance standard
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
12 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
1. Bracket
2. Cartridge
3. Safety valve
PC2000-8 13
SEN01618-05 10 Structure, function and maintenance standard
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}
14 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
1. Bracket Outline
2. Bypass 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 Bypass valve set pressure: 0.1 MPa {1.0 kg/cm2}
PC2000-8 15
SEN01618-05 10 Structure, function and maintenance standard
1. Head Outline
2. Bypass 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 Bypass valve set pressure:
147 ± 29 kPa {1.5 ± 0.3 kg/cm2}
16 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
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 17
SEN01618-05 10 Structure, function and maintenance standard
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}
18 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
PC2000-8 19
SEN01618-05 10 Structure, function and maintenance standard
System diagram
20 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
PC2000-8 21
SEN01618-05 10 Structure, function and maintenance standard
Solenoid valve 1
1. For back pressure compensation, 2-stage main relief, arm throttle, swing priority, straight travel, and
machine push-up
22 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
PC2000-8 23
SEN01618-05 10 Structure, function and maintenance standard
24 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
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.
PC2000-8 25
SEN01618-05 10 Structure, function and maintenance standard
3. For bucket high cancel, for bottom dump priority (If equipped)
26 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
PC2000-8 27
SEN01618-05 10 Structure, function and maintenance standard
28 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
PC2000-8 29
SEN01618-05 10 Structure, function and maintenance standard
Hydraulic cylinder 1
Backhoe specification
Boom cylinder
Arm cylinder
Bucket cylinder
30 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
Unit: mm
No. Check item Criteria Remedy
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 31
SEN01618-05 10 Structure, function and maintenance standard
Arm cylinder
Bucket cylinder
32 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
Unit: mm
No. Check item Criteria Remedy
Name of Standard Tolerance Standard Clearance
cylinder size Shaft Hole clearance limit
PC2000-8 33
SEN01618-05 10 Structure, function and maintenance standard
Greasing system 1
34 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
PC2000-8 35
SEN01618-05 10 Structure, function and maintenance standard
36 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
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 37
SEN01618-05 10 Structure, function and maintenance standard
Components
Grease pump
38 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
PC2000-8 39
SEN01618-05 10 Structure, function and maintenance standard
Hose reel
q The hose reel is used to store the grease gun
hose. It is the auto winder type.
40 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
1. Adjustment screw
2. Injector body
3. Injector piston
4. Piston spring
5. Slide valve
6. Manifold
PC2000-8 41
SEN01618-05 10 Structure, function and maintenance standard
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).
42 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
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 43
SEN01618-05 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Clearance between rotor and Standard size Standard clearance Clearance limit
6 Replace
shaft 110 0.056 – 0.105 0.111
44 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
PC2000-8 45
SEN01618-05 10 Structure, function and maintenance standard
46 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
Outline
q The ladder is raised and lowered hydraulically.
Raising ladder:
While the ladder raise switch is held
down, the ladder rises. The ladder is
raised only while the engine is running.
Lowering ladder:
While the ladder lower switch is held
down, the ladder lowers. The ladder is
lowered while the engine is running or
stopped (it lowers by its weight while
the engine is stopped).
q PPC lock function
While the ladder is in the storage position, the
proximity switches (upper 1 and 2) sense the
ladder position and reset the PPC lock. While
the ladder is not in the storage position, the
PPC lock operates.
q Automatic pressing function
While the ladder is near the storage position (in
the range between the vertical position and
slanting position of 5°), the proximity switch
(upper 2) senses the ladder position and the
ladder is pressed to the storage position auto-
matically. Accordingly, even if the ladder is
moved to the lower side by the vibration of the
machine, it is reset automatically. This function
works only while the engine is running.
q Automatic ladder lowering stop function
When the ladder lowers, the proximity switch
(lower) senses the standard lowering position
and stops the ladder automatically.
Standard lowering position: On a flat ground,
the ladder stops when the angle between the
ladder and ground is about 60° and the first
step of the ladder is about 380 mm above the
ground.
q Proximity switches (upper 1 and 2) warning
function
If either of the proximity switches (upper 1 and
2) has trouble, the proximity switch warning
lamp lights.
PC2000-8 47
SEN01618-05 10 Structure, function and maintenance standard
Switch box
Outline
If ladder raise switch (1) is pressed, the ladder rises
(only while the engine is running). If ladder lower
switch (2) is pressed, the ladder lowers (it lowers by
its weight while the engine is stopped).
If either of the proximity switches (upper 1 and 2)
has trouble, the proximity switch warning lamps (3)
or (4) lights.
a If warning lamp lights up, cope with it immedi-
ately referring to the "Operation & Mainte-
nance Manual". Ladder storage position
1. Ladder unit
2. Proximity switch (upper 1)
3. Proximity switch (upper 2)
4. Proximity switch (lower)
5. Sensor plate
Outline
Proximity switches (2), (3) and (4) sense sensor
plate (5) installed to ladder unit (1) to check the lad-
der position.
48 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
Outline
If the ladder raise switch or lower switch in the While the ladder lower switch is not pressed,
switch box is pressed, ladder lift operation selector hydraulic drift prevention valve (3) is closed to mini-
solenoid valve (2) opens and the hydraulic oil from mize the leakage in the circuit.
delivery port (P) flows to ladder cylinder bottom (C)
or ladder cylinder head (D) and the return oil flows
to return port (T).
PC2000-8 49
SEN01618-05 10 Structure, function and maintenance standard
1. Engine oil pan connection 8. Grease tank connection A. Service arm (when stored)
2. PTO connection 9. Grease shut-off valve B. Service arm (when lowered)
3. Swing machinery (front) connection (if equipped)
4. Swing machinery (rear) connection 10. Service arm cylinder P. Raise/Lower switch section
5. Hydraulic sub tank connection 11. Service arm operation Q. Proximity switch section
6. Radiator piping connection permission switch R. Control valve section
7. Fuel tank connection 12. Ladder and service arm S. Service panel section
warning lamp
50 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
Outline
q The service center can add and drain various oils and greases and coolant intensively from the ground.
q Executable items
Addition of fuel
Addition of grease
Addition and draining of hydraulic oil
Addition and draining of engine oil
Addition and draining of PTO oil
Addition and draining of swing machinery (front) oil
Addition and draining of swing machinery (rear) oil
Addition and draining of coolant
Automatic pressing
Proximity switch Service arm
Engine running ON pressed automatically
PC2000-8 51
SEN01618-05 10 Structure, function and maintenance standard
52 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
P. Delivery port
T. Return port
A. To service arm cylinder head
B. To service arm cylinder bottom
Outline
If the service arm raise switch or lower switch is
pulled, service arm raise/lower operation selector
solenoid valve (1) opens and the hydraulic oil from
delivery port (P) flows to service arm cylinder bot-
tom (B) or service arm cylinder head (A) and the
return oil flows to return port (T).
While the service arm lower switch is not pulled,
hydraulic drift prevention valve (2) is closed to mini-
mize the leakage inside the circuit.
PC2000-8 53
SEN01618-05 10 Structure, function and maintenance standard
Outline
Oils and coolant are added and drained through
couplers (2) to (9) on service panel (1).
The oil and coolant filler/drain couplers installed on
this panel are manufactured by WIGGINS. When
oil, grease and coolant are drained or added
through these couplers, a pressure feed pump and
its coupler must be kept on hand.
When delivered from the factory, the following cou-
plers are installed.
Coupler on
Coupler on pressure feed
panel side pump side
Swing machinery ON2 OS2 (*1)
(rear) oil coupler
Swing machinery ON2 OS2 (*1)
(front) oil coupler
PTO oil coupler ON2 OS2 (*1)
54 PC2000-8
10 Structure, function and maintenance standard SEN01618-05
PC2000-8 55
SEN01618-05
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 08-11
56
SEN01619-02
PC2000-8
PC2000-8 1
SEN01619-02 10 Structure, function and maintenance standard
Control valve 1
L.H. 10-spool valve
2 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
1. L1 valve
2. L2 valve
PC2000-8 3
SEN01619-02 10 Structure, function and maintenance standard
Sectional view
4 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
L1 valve
PC2000-8 5
SEN01619-02 10 Structure, function and maintenance standard
Sectional view
6 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
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
SEN01619-02 10 Structure, function and maintenance standard
8 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
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
SEN01619-02 10 Structure, function and maintenance standard
L2 valve
10 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
Sectional view
PC2000-8 11
SEN01619-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
× outside Free length
13 Spool return spring length load load
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
15 Check valve spring 78.2 × 26.6 52 —
{1.92 kg} {1.54 kg}
12.7 N 10.2 N
16 Check valve spring 20.8 × 12.2 13.5 —
{1.3 kg} {1.04 kg}
12 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
PC2000-8 13
SEN01619-02 10 Structure, function and maintenance standard
14 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
1. Arm Hi valve
2. Boom Hi valve
3. Bucket Lo valve
4. –
5. L.H. travel Lo valve
6. Safety-suction valve
7. Suction valve
PC2000-8 15
SEN01619-02 10 Structure, function and maintenance standard
16 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
1. R1 valve
2. R2 valve
PC2000-8 17
SEN01619-02 10 Structure, function and maintenance standard
Sectional view
18 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
R1 valve
PC2000-8 19
SEN01619-02 10 Structure, function and maintenance standard
Sectional view
20 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
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 21
SEN01619-02 10 Structure, function and maintenance standard
22 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
1. Arm Lo valve
2. Boom Hi valve
3. Bucket Lo valve
4. Swing valve
5. R.H. travel Hi valve
6. Safety-suction valve
7. Suction valve
PC2000-8 23
SEN01619-02 10 Structure, function and maintenance standard
R2 valve
24 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
Sectional view
PC2000-8 25
SEN01619-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
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}
26 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
PC2000-8 27
SEN01619-02 10 Structure, function and maintenance standard
28 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
1. Arm Hi valve
2. Boom Lo valve
3. Bucket Hi valve
4. –
5. R.H. travel Lo valve
6. Safety-suction valve
7. 2-stage safety-suction valve
8. Suction valve
PC2000-8 29
SEN01619-02 10 Structure, function and maintenance standard
30 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
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
SEN01619-02 10 Structure, function and maintenance standard
32 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
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.
PC2000-8 33
SEN01619-02 10 Structure, function and maintenance standard
Swing motor 1
Type: KMF230AB-5
34 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
PC2000-8 35
SEN01619-02 10 Structure, function and maintenance standard
36 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
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
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
× outside 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
SEN01619-02 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01619-02
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
SEN01619-02 10 Structure, function and maintenance standard
40 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
PC2000-8 41
SEN01619-02 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01619-02
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
× outside 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
SEN01619-02 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01619-02
2. Suction valve
PC2000-8 45
SEN01619-02 10 Structure, function and maintenance standard
46 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
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
SEN01619-02 10 Structure, function and maintenance standard
48 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
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.
1. Front pump
2. Rear pump
3. Gear pump
4. PC valve
5. EPC valve
6. Sequence valve
PC2000-8 49
SEN01619-02 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01619-02
PC2000-8 51
SEN01619-02 10 Structure, function and maintenance standard
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)
52 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
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
SEN01619-02 10 Structure, function and maintenance standard
1. PC valve
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
10 Structure, function and maintenance standard SEN01619-02
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
SEN01619-02 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01619-02
3) When PC mode selector current is increased (When EPC output pressure rises)
PC2000-8 57
SEN01619-02 10 Structure, function and maintenance standard
58 PC2000-8
10 Structure, function and maintenance standard SEN01619-02
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
SEN01619-02 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01619-02
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
SEN01619-02
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 08-11
62
SEN01620-02
PC2000-8
PC2000-8 1
SEN01620-02 10 Structure, function and maintenance standard
Travel motor 1
Type: KMF340-5
2 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
PC2000-8 3
SEN01620-02 10 Structure, function and maintenance standard
4 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
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
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
× outside Free length
16 Check valve spring length load load If damaged or
diameter
deformed,
6.96 N 6.57 N replace spring
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
SEN01620-02 10 Structure, function and maintenance standard
6 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
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
SEN01620-02 10 Structure, function and maintenance standard
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).
8 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
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
SEN01620-02 10 Structure, function and maintenance standard
2) Safety valve
(bidirectional 2-stage set safety valve)
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
10 Structure, function and maintenance standard SEN01620-02
(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.
PC2000-8 11
SEN01620-02 10 Structure, function and maintenance standard
12 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
PC2000-8 13
SEN01620-02 10 Structure, function and maintenance standard
Hydraulic pump 1
Type: HPV375+375
14 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
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.
1. Front pump
2. Rear pump
3. VC valve
4. EPC valve
5. Self pressure reducing valve
6. Filter
PC2000-8 15
SEN01620-02 10 Structure, function and maintenance standard
16 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
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
SEN01620-02 10 Structure, function and maintenance standard
18 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
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)
PC2000-8 19
SEN01620-02 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01620-02
Pump controller
System diagram
PC2000-8 21
SEN01620-02 10 Structure, function and maintenance standard
22 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
Servo valve
PC2000-8 23
SEN01620-02 10 Structure, function and maintenance standard
1. VC valve
24 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
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
SEN01620-02 10 Structure, function and maintenance standard
2. Servo piston
26 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
Outline
q Port (PA) pressure or port (PR) pressure,
whichever is higher, is applied to port (PH) by
the shuttle valve.
q Relation of pressure receiving area (A) of
chamber (a) and pressure receiving area (B) of
chamber (b) is expressed as (A) C [2 × (B)].
q Pressure of port (PH) is constantly applied to
chamber (b).
PA : Main pump discharge pressure
PR : Pilot basic pressure
PH : PA or PR pressure whichever is higher
Operation of VC valve
q The command current from the pump control-
ler is conducted to EPC solenoid (E1).
q This command current reduces the control
basic pressure applied to EPC valve (2).
q EPC valve (2) transmits the command current
specified pilot pressure.
q The pilot pressure goes to chamber (se1)
through port (SE1).
q Sleeve (4) of VC valve (1) is maintained at a
position where the EPC valve (2) pilot pressure
and the spring (5) force are balanced.
q The pump controller controls magnitude of the
command current sent to EPC valve (2).
PC2000-8 27
SEN01620-02 10 Structure, function and maintenance standard
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
28 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
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).
PC2000-8 29
SEN01620-02 10 Structure, function and maintenance standard
30 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
PC2000-8 31
SEN01620-02 10 Structure, function and maintenance standard
32 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
PC2000-8 33
SEN01620-02 10 Structure, function and maintenance standard
PPC valve 1
Work equipment and swing PPC valve 1
34 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
PC2000-8 35
SEN01620-02 10 Structure, function and maintenance standard
36 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
1. Spool
2. Piston
3. Disc
4. Nut (for connection of lever)
5. Joint
6. Plate
7. Retainer
8. Body
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
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 37
SEN01620-02 10 Structure, function and maintenance standard
38 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
PC2000-8 39
SEN01620-02 10 Structure, function and maintenance standard
40 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
PC2000-8 41
SEN01620-02 10 Structure, function and maintenance standard
42 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
1. Plate
2. Body
3. Piston
4. Seal
5. Centering spring
6. Metering spring
7. Valve
8. Damper
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
× outside 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 43
SEN01620-02 10 Structure, function and maintenance standard
44 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
PC2000-8 45
SEN01620-02 10 Structure, function and maintenance standard
46 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
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 47
SEN01620-02 10 Structure, function and maintenance standard
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).
48 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
PC2000-8 49
SEN01620-02 10 Structure, function and maintenance standard
50 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
1. Spool
2. Body
3. Flange
4. Retainer
5. O-ring
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed If damaged or
× outside Free length
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 51
SEN01620-02 10 Structure, function and maintenance standard
52 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
PC2000-8 53
SEN01620-02 10 Structure, function and maintenance standard
54 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
1. Block
2. Spool
3. Block
4. Spool
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed If damaged or
× outside 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 55
SEN01620-02 10 Structure, function and maintenance standard
56 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
1. Block
2. Spool
3. Block
Unit: mm
No. Check item Criteria Remedy
Basic dimensions Repair limit
Free length
Installed Installed Installed If damaged or
× outside 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 57
SEN01620-02 10 Structure, function and maintenance standard
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.
58 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
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 59
SEN01620-02 10 Structure, function and maintenance standard
Straight-travel function
1. When boom, arm, bucket or swing system other than travel system is operated.
(no travel operation)
Operation
q The straight travel solenoid valve does not out-
put pilot pressure, and the spools of straight
travel valve (PPC cut-off valve) CV1 and CV2
are in OPEN position.
q Output from arm, boom, bucket and left/right
travel PPC levers is led to L1, L2, R1 and R2
valves.
q 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.
60 PC2000-8
10 Structure, function and maintenance standard SEN01620-02
2. When travel system and boom, arm, bucket or swing system are operated
simultaneously.
(simultaneous operation of travel with other operation)
Operation
q The straight travel solenoid valve outputs pilot q L2 and R2 valves become pilot valves only for
pressure, and both spools of straight travel left and right travel, and L1 and R1 valves
valve (PPC cut-off valve) CV1 and CV2 are in become pilot valves only for work equipment
OFF position. and swing system.
q The pilot pressure from arm, boom, bucket and q Even if machine travels simultaneously with
left/right travel PPC valves are cut off, and work equipment or swing operation, oil flow to
spools below are not operated. left/right travel are not influenced, and straight
q Arm PPC valve: L2 valve and R2 valve travel is secured.
q Boom PPC valve: L2 valve and R2 valve
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 61
SEN01620-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 11-09 (01)
62
SEN01621-03
PC2000-8
PC2000-8 1
SEN01621-03 10 Structure, function and maintenance standard
Work equipment 1
Backhoe specification
2 PC2000-8
10 Structure, function and maintenance standard SEN01621-03
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
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 1.5
–0.106 +0.085 0.278
mounting pin and bushing
Clearance between
–0.043 +0.174 0.128 –
3 boom cylinder-revolving frame 180 1.5
–0.106 +0.085 0.280
mounting pin and bushing
Clearance between
–0.043 +0.160 0.128 –
4 boom-boom cylinder head 180 1.5
–0.106 +0.085 0.266
mounting pin and bushing
Clearance between
–0.043 +0.166 0.128 –
5 boom-boom cylinder head 180 1.5
–0.106 +0.085 0.272
mounting pin and bushing
Clearance between
–0.043 +0.172 0.128 –
6 boom-arm cylinder mounting 140 1.5
–0.106 +0.085 0.278
pin and bushing
Clearance between boom-arm –0.050 +0.581 0.520 –
7 200 1.5
mounting pin and bushing –0.122 +0.470 0.703
Clearance between boom-arm –0.050 +0.783 0.710 –
8 200 1.5
mounting pin and bushing –0.122 +0.660 0.905
Clearance between Replace
–0.043 +0.172 0.128 –
9 arm-arm cylinder mounting pin 140 1.5
–0.106 +0.085 0.278
and bushing
Clearance between
–0.036 +0.190 0.121 –
10 arm-bucket cylinder mounting 120 1.5
–0.090 +0.085 0.280
pin and bushing
Clearance between
–0.043 +0.408 0.335 –
11 link-bucket mounting pin and 140 1.5
–0.106 +0.292 0.514
bushing
Clearance between
–0.043 +0.2 0.043 –
12 link-bucket mounting pin and 140 1.5
–0.106 +0.0 0.306
bushing
Clearance between
–0.043 +0.393 0.349 –
13 bucket cylinder-link mounting 140 1.5
–0.106 +0.306 0.499
pin and bushing
Clearance between
–0.043 +0.1 0.043 –
14 bucket cylinder-link mounting 140 1.5
–0.106 +0.1 0.206
pin and bushing
Clearance between arm-link –0.043 +0.430 0.342 –
15 140 1.5
mounting pin and bushing –0.106 +0.299 0.536
Clearance between arm-link –0.043 +0.1 0.043 –
16 140 1.5
mounting pin and bushing –0.106 +0.1 0.206
Clearance between
–0.043 +0.421 0.382 –
17 arm-bucket mounting pin and 140 1.5
–0.106 +0.339 0.527
bushing
PC2000-8 3
SEN01621-03 10 Structure, function and maintenance standard
4 PC2000-8
10 Structure, function and maintenance standard SEN01621-03
Unit: mm
No. Check item Criteria Remedy
Clearance between Standard Tolerance Standard Clearance
1 boom-revolving frame size Shaft Hole clearance limit
mounting pin and bushing 180 — — — —
Clearance between
2 boom-arm mounting 160 — — — —
pin and bushing Replace
Clearance between
3 arm-bucket mounting 180 — — — —
pin and bushing
Clearance between
4 front bucket-rear bucket 170 — — — —
mounting pin and bushing
PC2000-8 5
SEN01621-03 10 Structure, function and maintenance standard
6 PC2000-8
10 Structure, function and maintenance standard SEN01621-03
Unit: mm
PC2000-8
No.
3.9 m arm
1 (140)
2 110 –20
0
3 936 –0.5
4 (200)
5 489 ± 1
6 672.8 ± 1
7 1199 ± 1
8 3,841.7
9 5,103 ± 2
10 719 ± 1
11 1,300 ± 0.5
12 1,210 ± 0.5
13 955.2 ± 0.7
14 3,900
15 (140)
0
16 364 –0.5
17 (140)
0
Arm as individual part 348 –0.5
18 0
When press-fitting bushing 364 –0.9
Min. 3,250
19
Max. 5,420
20 124 ± 1
PC2000-8 7
SEN01621-03 10 Structure, function and maintenance standard
2. Bucket
8 PC2000-8
10 Structure, function and maintenance standard SEN01621-03
Unit: mm
PC2000-8
No.
12 m3 bucket
1 940 ± 0.5
2 170 ± 0.5
3 100°
4 955.2 ± 0.7
5 3,076
6 524
+3
7 1,322 –5
8 410 ± 1
9 330 –0.7
–0.9
10 165
11 71
12 86 ± 0.5
13 20
14 365 ± 0.5
15 370 ± 0.5
16 98
17 88
18 218
19 233
20 R180
21 R130
22 φ160 +0.1
0
23 φ185 +0.115
0
24 φ140 +0.2
0
25 φ326
26 φ220
27 25°
28 134
29 55 +10
30 φ248 +10
31 R1000
32 3,120
2,600: Wothout side shroud
33
2,670: With side shroud
34 212
35 352
36 135
M×P M36 × 3
PC2000-8 9
SEN01621-03
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
10
SEN01622-01
PC2000-8
PC2000-8 1
SEN01622-01 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01622-01
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
SEN01622-01 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01622-01
PC2000-8 5
SEN01622-01
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 08-11
6
SEN01623-03
PC2000-8
PC2000-8 1
SEN01623-03 10 Structure, function and maintenance standard
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.
When battery isolator and starting motor isolator (optional) are installed
2 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
When battery isolator and starting motor isolator (optional) are installed
PC2000-8 3
SEN01623-03 10 Structure, function and maintenance standard
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.
When battery isolator and starting motor isolator (optional) are installed
4 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
Component
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
SEN01623-03 10 Structure, function and maintenance standard
6 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
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
SEN01623-03 10 Structure, function and maintenance standard
8 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
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(*) A 20 NC(*) —
36 NC(*) — 21 NC(*) —
37 5 V electric power supply for sensor A 22 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
SEN01623-03 10 Structure, function and maintenance standard
10 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 11
SEN01623-03 10 Structure, function and maintenance standard
12 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
NC flow control
Electronic CLSS function PC characteristic flow control
Cut-off control
Cut-off reset
Emergency pump drive
ON
ON
Compound operation
compensation function
14
Fan reverse function
PC2000-8 13
SEN01623-03 10 Structure, function and maintenance standard
System diagram
14 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 15
SEN01623-03 10 Structure, function and maintenance standard
16 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 17
SEN01623-03 10 Structure, function and maintenance standard
18 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
Auto-deceleration function
PC2000-8 19
SEN01623-03 10 Structure, function and maintenance standard
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.
20 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 21
SEN01623-03 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 23
SEN01623-03 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 25
SEN01623-03 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01623-03
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.
PC2000-8 27
SEN01623-03 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01623-03
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.
PC2000-8 29
SEN01623-03 10 Structure, function and maintenance standard
30 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
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 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 — — — —
PC2000-8 31
SEN01623-03 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01623-03
⇒ ⇒
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 Engine speed: Keep as is. hydraulic oil temperature below 95°C
temperature: Monitor alarm lamp: Does not light • Under above condition, controller is
Above 95°C Alarm buzzser: Does not sound set to condition before operation of
Lower travel speed. function. (Automatic reset)
PC2000-8 33
SEN01623-03 10 Structure, function and maintenance standard
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
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
10 Structure, function and maintenance standard SEN01623-03
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
SEN01623-03 10 Structure, function and maintenance standard
Operation
When boom, arm, bucket or swing system other
than travel system is operated.
(no travel operation)
q The straight travel solenoid valve does not out- q Accordingly, the travel spool of valve L1,
put pilot pressure, and the spools of straight bucket, boom and arm spools of valve L2,
travel valve (PPC cut-off valve) CV1 and CV2 travel spool of valve R1, bucket, boom and arm
are in OPEN position. spools of valve R2 are operated.
q 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.
36 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
Operation
When travel system and boom, arm, bucket or
swing system are operated simultaneously.
(simultaneous operation of travel with other
operation)
q The straight travel solenoid valve outputs pilot
pressure, and both spools of straight travel
valve (PPC cut-off valve) CV1 and CV2 are in
OFF position, then the output from the PPC
levers of arm, boom, bucket and left/right travel
systems are cut off.
q By switching spool positions of straight travel
PPC cut-off valve (CV1, CV2), the travel spool
of L1 and R1 valves are in NEUTRAL position
and pilot pressure for travel is cut off, then L1
and R1 valves become pilot valves only for
work equipment and swing system. At the
same time, the work equipment spool of L2
and R2 valves are in NEUTRAL position and
pilot pressure for work equipment is cut off,
then L2 and R2 valves become pilot valve only
for travel system.
PC2000-8 37
SEN01623-03 10 Structure, function and maintenance standard
Operation
q If the swing PPC pressure exceeds 0.78 MPa
{8 kg/cm 2} and the arm or bucket PPC pres-
sure exceeds 0.49 MPa {5 kg/cm2}, the control-
ler energizes the swing priority solenoid valve,
which outputs oil of 2.94 MPa {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
10 Structure, function and maintenance standard SEN01623-03
Operation
q If the swing PPC pressure exceeds 0.78 MPa
{8 kg/cm2} and the boom raise PPC pressure
exceeds 0.49 MPa {5 kg/cm2}, the controller
energizes the boom throttle solenoid valve,
which outputs oil of 2.94 MPa {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
SEN01623-03 10 Structure, function and maintenance standard
40 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 41
SEN01623-03 10 Structure, function and maintenance standard
42 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
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
SEN01623-03 10 Structure, function and maintenance standard
Unit: mm
Criteria
Standard size Repair limit
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,
231.4 N 185.3 N replace spring
3 Spring (3) 116.18 × 19.5 90 —
{23.6 kg} {18.9 kg}
44 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 45
SEN01623-03 10 Structure, function and maintenance standard
46 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 47
SEN01623-03 10 Structure, function and maintenance standard
Pump controller
Pump controller 1
48 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 49
SEN01623-03 10 Structure, function and maintenance standard
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
24 PWR_CTR_KEY 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
10 Structure, function and maintenance standard SEN01623-03
Pump controller 2
PC2000-8 51
SEN01623-03 10 Structure, function and maintenance standard
52 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
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
14 PWR_CTR_KEY 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
24 PWR_CTR_KEY 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
SEN01623-03 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01623-03
Monitor system 1
PC2000-8 55
SEN01623-03 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01623-03
CN-CM01 CN-CM04
Input/ Input/
Pin No. Signal name Pin No. Signal name
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
SEN01623-03 10 Structure, function and maintenance standard
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
58 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 59
SEN01623-03 10 Structure, function and maintenance standard
Engine coolant
temperature
Hydraulic oil
temperature
Fuel level See gauge display on next page.
PTO oil
temperature
Engine oil
Pressure
60 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
PC2000-8 61
SEN01623-03 10 Structure, function and maintenance standard
q Engine oil pressure is measured from engine speed by engine controller, and when abnormal, the
gauge indicates the middle between F5 and F6 regardless of the value.
62 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
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.
Lights up when
Battery charge q —
abnormal.
Lights up when
Engine oil level q abnormal.
—
Lights up when
Air cleaner clogging q —
abnormal.
PC2000-8 63
SEN01623-03 10 Structure, function and maintenance standard
64 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
a: If another caution is displayed, these items are displayed only when abnormal.
PC2000-8 65
SEN01623-03 10 Structure, function and maintenance standard
Display
Symbol Display item Display range Display method
category
66 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 67
SEN01623-03 10 Structure, function and maintenance standard
Switches 1
68 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
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).
PC2000-8 69
SEN01623-03 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 71
SEN01623-03 10 Structure, function and maintenance standard
72 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
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.
PC2000-8 73
SEN01623-03 10 Structure, function and maintenance standard
74 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
1) Time setting
Set the clock time. If the time setting item
is not highlighted, press F6 to highlight it.
PC2000-8 75
SEN01623-03 10 Structure, function and maintenance standard
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.
76 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 77
SEN01623-03 10 Structure, function and maintenance standard
78 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
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.
PC2000-8 79
SEN01623-03 10 Structure, function and maintenance standard
80 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 81
SEN01623-03 10 Structure, function and maintenance standard
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.
82 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
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
PC2000-8 83
SEN01623-03 10 Structure, function and maintenance standard
Detail of sensor
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
1. Float
2. Switch
3. Connector
4. Variable resistor
84 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
PC2000-8 85
SEN01623-03 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN01623-03
1. Sensor
2. Connector
1. Block
2. Sensor
3. Wire
4. Connector
PC2000-8 87
SEN01623-03 10 Structure, function and maintenance standard
1. Sensor
2. Connector
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
10 Structure, function and maintenance standard SEN01623-03
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
PC2000-8 89
SEN01623-03 10 Structure, function and maintenance standard
90 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
PC2000-8 91
SEN01623-03 10 Structure, function and maintenance standard
VHMS controller
92 PC2000-8
10 Structure, function and maintenance standard SEN01623-03
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
PC2000-8 93
SEN01623-03 10 Structure, function and maintenance standard
CN3 CN4
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
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
10 Structure, function and maintenance standard SEN01623-03
ORBCOMM terminal 1
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
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
1 NC Input 15 NC Output
2 NC Output 16 NC Input
3 NC Input 17 NC Input
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
8 NC Input/Output 22 NC Input
9 NC — 23 NC Input
10 NC Input/Output 24 NC Input
11 GND_232C — 25 NC Input
12 NC Input 26 NC Input
13 NC Input 27 NC Input
14 NC Output 28 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
SEN01623-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 11-09 (01)
96
SEN02006-03
PC2000-8
PC2000-8 1
SEN02006-03 20 Standard value table
Engine SAA12V140E-3
Category
Standard
Service limit
Item Measurement conditions Unit value for new
value
machine
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
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
20 Standard value table SEN02006-03
PC2000-8
Applicable model
(Backhoe specification)
Category
• Engine stopped
Bucket control lever • Center of lever N o Curl, Dump 85 ± 10 85 ± 10
knob
• Read max. value
Swing control lever to end of travel N o R.H., L.H. 85 ± 10 85 ± 10
(Exclude play at
neutral.) N o F, R
Travel control lever 115 ± 12 115 ± 12
(L.H., R.H.)
Work equip-
Play of control levers ment, swing, Max. 10 Max. 15
travel
PC2000-8 3
SEN02006-03 20 Standard value table
PC2000-8
Applicable model
(Backhoe specification)
Category
–20
+1.0
32.5 ± 1.0 32.5
–2.0
At heavy lift
{332 ± 10} +10
{332 –20
}
Boom relief pressure • Hydraulic oil tem-
perature: 45 – 12.3 ± 2.0 12.3 ± 2.0
55°C Normal
{125 ± 20} {125 ± 20}
LOWER
• Engine at high
idle
• Working mode: P At machine 27.9 ± 2.0 27.9 ± 2.0
• Pump outlet push-up {285 ± 20} {285 ± 2.0}
pressure when
measured circuit +1.0
29.7 ± 1.0 29.7
is relieved –2.0
Arm relief pressure
{303 ± 10} +10
Hydraulic pressure
+1.0
29.7 ± 1.0 29.7
–2.0
Swing relief pressure
{303 ± 10} +10
{303 –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 tem- All control levers Max. 0.59 Max. 0.59
perature: 45 – at neutral {Max. 6} {Max. 6}
Pump EPC solenoid
55°C
valve output
• Engine at high Travel under no
pressure 1.11/2.04 ± 0.39 1.11/2.04 ± 0.39
idle load (Lever full)
• Working mode: P {11.3/20.8 ± 4.0} {11.3/20.8 ± 4.0}
(P1/P2)
4 PC2000-8
20 Standard value table SEN02006-03
PC2000-8
Applicable model
(Backhoe specification)
Category
PC2000-8 5
SEN02006-03 20 Standard value table
PC2000-8
Applicable model
(Backhoe specification)
Category
• Travel speed: Lo
Travel deviation • On hard and level ground mm Max. 200 Max. 220
• Measure travel deviation (x) in travel
of 20 m after running up 10 m.
• For measuring posture, see Travel 2
and 3.
• Hydraulic oil temperature: 45 – 55°C
• Engine stopped
• Stop machine on 12° slope with
Hydraulic drift of travel sprocket at uphill end of machine. mm 0 0
• Measure the distance the machine
moves in 5 minutes.
• For measuring posture, see Travel 4.
• Hydraulic oil temperature: 45 – 55°C
• Engine at high idle
• Travel: Lock sprocket with lock pin
Leakage of travel
(a). l/min Max. 25 Max. 30
motor
• Measure leakage in 1 minute during
travel relief.
• For measuring posture, see Travel 5.
6 PC2000-8
20 Standard value table SEN02006-03
PC2000-8
Applicable model
(Backhoe specification)
Category
PC2000-8 7
SEN02006-03 20 Standard value table
PC2000-8
Applicable model
(Backhoe specification)
Category
sec.
Arm • Hydraulic oil temperature: 45 – 55°C Max. 5 Max. 5
• For measuring posture, see Work
equipment 6.
• Time from stop of bucket to start.
• Run engine at slow speed.
Bucket • Hydraulic oil temperature: 45 – 55°C Max. 4 Max. 4
• For measuring posture, see Work
equipment 7.
Oil leakage
Delivery amount of
• See next page l/min See next page
hydraulic pump
8 PC2000-8
20 Standard value table SEN02006-03
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
PC2000-8 9
SEN02006-03 20 Standard value table
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
10 PC2000-8
20 Standard value table SEN02006-03
Posture of machine for measuring performance Travel 1: Travel speed (without load)
and measurement procedure
PC2000-8 11
SEN02006-03 20 Standard value table
Work equipment 1: Hydraulic drift of work Work equipment 4: Bucket speed (empty)
equipment
12 PC2000-8
20 Standard value table SEN02006-03
PC2000-8 13
SEN02006-03 20 Standard value table
PC2000-8
Applicable model
(Loading shovel specification)
Category
• Engine stopped
Bucket control lever • Center of lever N o Curl, Dump 85 ± 10 85 ± 10
knob
• Read max. value
Swing control lever to end of travel N o R.H., L.H. 85 ± 10 85 ± 10
(Exclude play at
neutral.) N o F, R
Travel control lever 115 ± 12 115 ± 12
(L.H., R.H.)
Work equip-
Play of control levers ment, swing, Max. 10 Max. 15
travel
14 PC2000-8
20 Standard value table SEN02006-03
PC2000-8
Applicable model
(Loading shovel specification)
Category
–20
+1.0
32.5 ± 1.0 32.5
–2.0
At heavy lift
{332 ± 10} +10
{332 –20
}
Boom relief pressure • Hydraulic oil tem-
perature: 45 – 12.3 ± 2.0 12.3 ± 2.0
55°C Normal
{125 ± 20} {125 ± 20}
LOWER
• Engine at high
idle
• Working mode: P At machine 27.9 ± 2.0 27.9 ± 2.0
• Pump outlet push-up {285 ± 20} {285 ± 2.0}
pressure when
measured circuit +1.0
29.7
Hydraulic pressure
+1.0
29.7 ± 1.0 29.7
–2.0
Swing relief pressure
{303 ± 10} +10
{303 –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
}
+1.0
29.4 ± 1.0 29.4
–2.0
Open
{300 ± 10} +10
{300 –20
}
Bottom dump relief
pressure +1.0
20.1 ± 1.0 20.1
–2.0
Close
205 ± 10 +10
{205 –20
}
PC2000-8 15
SEN02006-03 20 Standard value table
PC2000-8
Applicable model
(Loading shovel specification)
Category
+0.49 +0.49
• Hydraulic oil temperature: 45 – 55°C 3.24 3.24
–0 –0.20
Control pressure
• Engine at high idle +5 +5
{33 0 } {33 –2 }
• Hydraulic oil tem- All control levers Max. 0.59 Max. 0.59
perature: 45 – at neutral {Max. 6} {Max. 6}
Pump EPC solenoid
55°C
valve output
• Engine at high Travel under no
pressure 1.11/2.04 ± 0.39 1.11/2.04 ± 0.39
idle load (Lever full)
Hydraulic pressure
16 PC2000-8
20 Standard value table SEN02006-03
PC2000-8
Applicable model
(Loading shovel specification)
Category
PC2000-8 17
SEN02006-03 20 Standard value table
PC2000-8
Applicable model
(Loading shovel specification)
Category
18 PC2000-8
20 Standard value table SEN02006-03
PC2000-8
Applicable model
(Loading shovel specification)
Category
LOWER (*)RAISE
Boom • Run engine at full throttle.
Lower bucket • Set in mode P 8.3 ± 0.8 Max. 10.0
tooth to ground. • Hydraulic oil temperature: 45 – 55°C
• For measuring posture, see
Work equipment 2.
Extract cylinder to • *:Including cylinder cushion 7.0 ± 0.7 Max. 8.4
stroke end. operating time.
IN
Retract cylinder to • Set in mode P 5.3 ± 0.5 Max. 6.4
stroke end. • Hydraulic oil temperature: 45 – 55°C
Work equipment speed
(*)OUT
Work equipment 3.
Extract cylinder to *: Including cylinder cushion oper- 3.2 ± 0.3 Max. 3.8
stroke end. ating time. sec
PC2000-8 19
SEN02006-03 20 Standard value table
PC2000-8
Applicable model
(Loading shovel specification)
Work equipment Category
Delivery amount of
• See next page l/min See next page
hydraulic pump
20 PC2000-8
20 Standard value table SEN02006-03
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
PC2000-8 21
SEN02006-03 20 Standard value table
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
22 PC2000-8
20 Standard value table SEN02006-03
Posture of machine for measuring performance Travel 1: Travel speed (without load)
and measurement procedure
PC2000-8 23
SEN02006-03 20 Standard value table
Work equipment 1: Hydraulic drift of work Work equipment 4: Bucket speed (empty)
equipment
24 PC2000-8
20 Standard value table SEN02006-03
Work equipment 5: Boom time lag Work equipment 8: Bottom dump cylinder speed
Work equipment 9: Bottom dump cylinder time lag
PC2000-8 25
SEN02006-03
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
26
SEN02007-04
PC2000-8
PC2000-8 1
SEN02007-04 30 Testing and adjusting
2 PC2000-8
30 Testing and adjusting SEN02007-04
symbol
Testing and adjusting
Q’ty
Part No. Part name Remarks
item
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 7 MPa {0 to 70 kg/cm2}
Measuring compres-
D 795-471-1330 Adapter 1 For 140E-3, 5 engine
sion pressure 2
6261-71-6150 Gasket 1 For 140E-3, 5 engine
1 799-201-1504 Blow-by checker kit 1 0 – 10 kPa {0 – 1,000 mmH2O}
2 799-201-1590 Gauge 1
Measuring blow-by
E 3 799-201-1450 Adapter 2
pressure
4 799-201-1511 Nozzle 2
5 799-201-1571 Tube 1
Pressure gauge: 2.5, 6, 40, 60 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: 60 MPa {600 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
PC2000-8 3
SEN02007-04 30 Testing and adjusting
symbol
Testing and adjusting
Q’ty
Part No. Part name Remarks
item
Measuring PPC valve 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 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 Size: 04
3
02896-11012 O-ring 1
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 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
1 799-608-3101 Service kit 1
2 799-608-3211 • Diskette 1
3 799-608-3220 • Harness 1
VHMS controller initial
W
setting procedure Commercially Note type personal
4 1 OS: Windows 98/2000/Me/XP/Vista
available computer
Commercially RS232C-USB conver-
5 1
available sion cable
4 PC2000-8
30 Testing and adjusting SEN02007-04
symbol
Testing and adjusting
Q’ty
Part No. Part name Remarks
item
PC2000-8 5
SEN02007-04 30 Testing and adjusting
6 PC2000-8
30 Testing and adjusting SEN02007-04
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
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.
PC2000-8 7
SEN02007-04 30 Testing and adjusting
8 PC2000-8
30 Testing and adjusting SEN02007-04
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.
PC2000-8 9
SEN02007-04 30 Testing and adjusting
10 PC2000-8
30 Testing and adjusting SEN02007-04
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
PC2000-8 11
SEN02007-04 30 Testing and adjusting
12 PC2000-8
30 Testing and adjusting SEN02007-04
PC2000-8 13
SEN02007-04 30 Testing and adjusting
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}
14 PC2000-8
30 Testing and adjusting SEN02007-04
PC2000-8 15
SEN02007-04 30 Testing and adjusting
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.
16 PC2000-8
30 Testing and adjusting SEN02007-04
PC2000-8 17
SEN02007-04 30 Testing and adjusting
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
18 PC2000-8
30 Testing and adjusting SEN02007-04
PC2000-8 19
SEN02007-04 30 Testing and adjusting
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
Symbol Part No. Part name
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
20 PC2000-8
30 Testing and adjusting SEN02007-04
PC2000-8 21
SEN02007-04 30 Testing and adjusting
22 PC2000-8
30 Testing and adjusting SEN02007-04
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.
PC2000-8 23
SEN02007-04 30 Testing and adjusting
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.
24 PC2000-8
30 Testing and adjusting SEN02007-04
PC2000-8 25
SEN02007-04 30 Testing and adjusting
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.
26 PC2000-8
30 Testing and adjusting SEN02007-04
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 electric 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.
PC2000-8 27
SEN02007-04 30 Testing and adjusting
q Left bank
q Right bank
28 PC2000-8
30 Testing and adjusting SEN02007-04
Testing fuel system for leakage 1 a If any fuel leakage is detected, repair it
and inspect again from step 1.
a
k
If no fuel leakage is detected, check is
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.
PC2000-8 29
SEN02007-04 30 Testing and adjusting
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}: 20 mm after one-hour operation.
30 PC2000-8
30 Testing and adjusting SEN02007-04
Testing procedure 1. Loosen nuts and bolts (1), (2), (3) and (4) in
1. Dismount belt covers (7) and (8). this order.
PC2000-8 31
SEN02007-04 30 Testing and adjusting
32 PC2000-8
30 Testing and adjusting SEN02007-04
PC2000-8 33
SEN02007-04
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 03-11
34
SEN02008-05
PC2000-8
PC2000-8 1
SEN02008-05 30 Testing and adjusting
2 PC2000-8
30 Testing and adjusting SEN02008-05
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)
PC2000-8 3
SEN02008-05 30 Testing and adjusting
4 PC2000-8
30 Testing and adjusting SEN02008-05
Gas filling in HIC circuit 2. Attach the plug (4) to the accumulator (3).
accumulator
PC2000-8 5
SEN02008-05 30 Testing and adjusting
7. After filling nitrogen gas to the specified pres- Serial No.: 20198 and up
sure, tighten the valve [7] firmly. 1. Relieve pressure remaining in the HIC circuit.
a Specified pressure: a Refer to the Paragraph of “Remaining
13.2 ± 0.3 MPa {135 ± 3 kg/cm2} pressure relief from HIC circuit” and leave
(Atmospheric temperature: 20 ± 3°C) 2 pieces of the drain valve (1) loosened.
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.
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”.
3. Attach the valve kit [1] of the charge valve
assembly M to accumulator (2) and attach the
nipple [2] to nitrogen cylinder (4). Then, con-
nect 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.
6 PC2000-8
30 Testing and adjusting SEN02008-05
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 7
SEN02008-05 30 Testing and adjusting
Bleeding air from HIC circuit and 3. Fully open stop valve (3) on the rear side of the
supplying oil to it 1 frame (lower part of the swing circle).
8 PC2000-8
30 Testing and adjusting SEN02008-05
PC2000-8 9
SEN02008-05 30 Testing and adjusting
Serial No.: 20198 and up 3. Loosen air bleeding plug (3) of the cushion cyl-
Before adding grease to the grease cylinder, be inder about 1 turn (2 places on the right and
sure to release the air from and charge oil to the left).
HIC circuit.
10 PC2000-8
30 Testing and adjusting SEN02008-05
6. If clear transparent oil flows out of air bleeding 8. Tighten plugs (1) (at 2 places on the right and
plugs (3) (two placed on the right and left) and left).
the hole of plug (5) at the bottom of check 3 Plug: 58.8 – 88.3 Nm {6 – 9 kgm}
valve block (4), tighten drain valve (2) and air
bleeding plugs (3) and (6) securely.
3 Air bleeding plug:
58.8 – 88.3 Nm {6 – 9 kgm}
PC2000-8 11
SEN02008-05 30 Testing and adjusting
12 PC2000-8
30 Testing and adjusting SEN02008-05
3) Turn the fuel control dial to the medium 8) Fully close stop valve (4).
position and run the engine at medium
speed.
4) Stick the bucket tooth into the ground so
that the machine cannot travel.
5) Operate the right travel lever forward and
reverse travels and relieve the oil for two –
three seconds. Repeat this operation five
– six 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 5) securely.
6) Check that projection (a) of the plunger (7)
of hydraulic cushion cylinder is 135 ± 5
mm on each side.
7) If projection (a) is not 135 ± 5 mm, perform
the operation in 5) again to set projection
(a) in the specified range.
<Check point>
If the end of plunger (7) of the hydraulic
cushion cylinder is about the center of the
inspection hole of on the side of the track
frame, projection "a" is almost within the
specified range.
a If projection (a) cannot be set to 135 ±
5 mm, too much grease may be in
grease cylinder (6). In this case, dis-
charge the grease according to “2.
Adjusting grease cylinder”.
PC2000-8 13
SEN02008-05 30 Testing and adjusting
14 PC2000-8
30 Testing and adjusting SEN02008-05
PC2000-8 15
SEN02008-05 30 Testing and adjusting
16 PC2000-8
30 Testing and adjusting SEN02008-05
q VR valve
PC2000-8 17
SEN02008-05 30 Testing and adjusting
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}
18 PC2000-8
30 Testing and adjusting SEN02008-05
PC2000-8 19
SEN02008-05 30 Testing and adjusting
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
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.
20 PC2000-8
30 Testing and adjusting SEN02008-05
PC2000-8 21
SEN02008-05 30 Testing and adjusting
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 6 MPa
{60 kg/cm2}.
a Devices for inspecting and measuring main
pump control signal
Symbol Part Number Part Name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
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:
q Hydraulic oil temperature: 45 – 55°C
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.
22 PC2000-8
30 Testing and adjusting SEN02008-05
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.
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24 PC2000-8
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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.
q Hydraulic oil temperature: 45 – 55°C
1) Run the engine at high idle and measure
the EPC current with the fan 100% speed
mode.
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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 6 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
measuring instruments and return the
799-101-5002 Hydraulic tester removed parts.
1
790-261-1204 Digital hydraulic tester
S
799-101-5220 Nipple (Max. 1.5 mm)
2
07002-11023 O-ring
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28 PC2000-8
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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
Symbol Part Number Part Name
points with “oil pressure gauges”.
799-101-5002 Hydraulic tester
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
2. Measuring fan pump discharge pressure a Measuring tools for jet sensor differential pres-
sure
Symbol Part Number Part Name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Differential pressure
— 2 799-401-2701
gauge
799-101-5220 Nipple (M10 x 1.25 mm)
3
07002-11023 O-ring
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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
Symbol Part Number Part Name
of the control circuit, the valve is normal.
799-101-5002 Hydraulic tester
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
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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
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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.
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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.
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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
42 PC2000-8
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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.
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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 a When removing and installing the work
hydraulic pumps and make sure that bub- equipment cylinder or when disconnecting
ble-free oil flows out of them. Then, and connecting the cylinder circuit piping,
tighten these bleeders temporarily. bleed air from the work equipment cylinder
11) Close the oil filler caps of the hydraulic according to the following procedures.
tank. k If air was not bled or air was bled insuf-
12) Keep the engine idling at low speed, raise ficiently, the cylinder piston ring may
the work equipment from the ground and be broken. So, be sure to bleed air
swing the upper structure 180°. strictly according to the procedures.
a After the swing, lower the work equip- 1) Start the engine and idle it at low speed for
ment completely to the ground. about 5 minutes.
13) Loosen plug (5) for the suction tube and 2) Repeat raising and lowering the boom 4 or
make sure that bubble-free oil flows out of 5 times at the low idle.
it. Then, tighten the plug. a Stop the piston rod about 100mm
3 Plug : 58.8 – 78.4Nm {6 – 8kgm} before the stroke end and be careful
14) Loosen the bleeders (1) – (3) of all not to relieve it.
hydraulic pumps and make sure that bub- 3) Execute Step 2) at high idle.
ble-free oil flows out of them. Then, 4) Bring the piston rod to the stroke end at
tighten these bleeders temporarily. low idle and relieve it.
a This work is the same as in the above 5) Execute Steps 2) – 4) for the arm and the
Step 10. bucket.
15) Keep the engine idling at low speed, raise a When the cylinder was replaced, execute
the work equipment from the ground and the procedures before connecting the
swing the upper structure 180°. work equipment. Especially, when the
a Swing the upper structure in the boom cylinder was installed to the work
reverse direction from the one in the equipment, the lowering side does not
above Step 12. After the swing, lower move to the stroke end.
the work equipment completely to the
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.
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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.
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5. Air Bleeding from travel motor circuit 6. Bleeding air from PPC circuit
(Travel motor) a If the control valve was removed and
installed or the PPC hose was discon-
nected and connected, bleed air from the
PPC circuit according to the following pro-
cedure.
k If air is not bled at all or completely, a
time lag may be made or abnormal
sound may come out from the PPC
valve. Accordingly, be sure to bleed air
according to the given procedure.
1) Start the engine and loosen the bleeders
(13) (see item 4) and illustration on the
next page).
a The bleeders are installed to the
spring case elbow of the control valve
spool.
a When removing and installing the travel (28 places in total)
motor or when disconnecting and con- 2) While running the engine at low idle, oper-
necting the travel motor main circuit pipes, ate each actuator to bleed air.
bleed air from the travel motor according 3) Ensure that oil containing no bubble flows
to the following procedures. out of the bleeder and then tighten the
k If air was not bled or air was bled insuf- bleeder.
ficiently, the travel motor may be dam- 3 Bleeder :
aged. So, be sure to bleed air strictly 8.8 – 9.8 Nm {0.9 – 1.0 kgm}
according to the procedures. k Operate each lever only to a
1) Start the engine and loosen bleeder (12). degree that the corresponding oil
a The bleeder is mounted on the LH pressure switch is turned ON.
and RH travel motors. 4) Bleed air from the following circuits at the
2) Make sure that bubble-free oil flows out of shown places.
the bleeders (12). Then, tighten the A : Arm IN circuit (3 places),
bleeder. Q : Boom RAISE circuit (3 places),
3 Bleeder : T : Bucket CURL circuit (4 places),
8.8 – 9.8Nm {0.9 – 1.0kgm} 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)
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48 PC2000-8
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7. Bleeding air from pilot selector valve circuit 4) While running the engine at low idle, raise
the boom and swing the upper structure
a If the pilot selector valve circuit was dis- simultaneously. When oil containing no
connected and connected, bleed air from bubbles flows out of bleeder (2), tighten
it according to the following procedure. bleeder (2).
k If the air bleeding operation is not per- 3 Bleeder:
formed or all air is not bled, the work 8.8 – 9.8 Nm {0.9 – 1.0 kgm}
equipment speed may decrease during k Operate each lever slightly to a
compound operation. Therefore, be d eg r ee th at each o i l p r essu r e
sure to bleed air according to the spec- switch is turned ON.
ified procedure.
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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.
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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.
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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°
54 PC2000-8
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PC2000-8 59
SEN02008-05
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 09-10
60
SEN02009-05
PC2000-8
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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)
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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”.
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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
order of “ON” — “OFF” — “ON” each time the
auto-deceleration switch is pressed.
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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.
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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.
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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.
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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.
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1. Selecting menu
Select “Abnormality Record” on the “Service
Menu” screen.
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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)
q [F3]: Move to lower item
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.
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1. Selecting menu
Select “Phone Number Entry” on the “Service
Menu” screen.
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1. Selecting menu
Select “Default” on the “Service Menu” screen.
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For the adjustment items, codes and set values, see the following table.
Item Code Default Set value Adjustment value
Main pump absorption torque 022 000 392 Nm {40 kgm}
001 294 Nm {30 kgm}
002 196 Nm {20 kgm}
003 98 Nm {10 kgm}
Q 004 0 Nm {0 kgm}
005 -98 Nm {-10 kgm}
006 -196 Nm {-20 kgm}
007 -294 Nm {-30 kgm}
008 -392 Nm {-40 kgm}
Auto grease pump discharge pressure adjustment 080 000 2 MPa {20 kg/cm2}
001 1.5 MPa {15 kg/cm2}
002 1 MPa {10 kg/cm2}
003 0.5 MPa {5 kg/cm2}
Q 004 0 MPa {0 kg/cm2}
005 -0.5 MPa {-5 kg/cm2}
006 -1 MPa {-10 kg/cm2}
007 -1.5 MPa {-15 kg/cm2}
008 -2 MPa {-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
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46 PC2000-8
30 Testing and adjusting SEN02009-05
PC2000-8 47
SEN02009-05 30 Testing and adjusting
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
48 PC2000-8
30 Testing and adjusting SEN02009-05
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.
PC2000-8 49
SEN02009-05 30 Testing and adjusting
50 PC2000-8
30 Testing and adjusting SEN02009-05
PC2000-8 51
SEN02009-05 30 Testing and adjusting
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.
52 PC2000-8
30 Testing and adjusting SEN02009-05
4. Finishing measurement
Press [F1], and measurement is finished and
the data are displayed on the finishing date
and time side.
PC2000-8 53
SEN02009-05 30 Testing and adjusting
54 PC2000-8
30 Testing and adjusting SEN02009-05
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)
2
3 Engine oil pressure kPa kg/cm 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)
2/12 1 Engine speed r/min rpm rpm ENG
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
6 L/B 4-6 exhaust temperature °C °C °F VHMS
3/12 1 Engine speed r/min rpm rpm ENG
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
6 L/B 1-3 exhaust temperature °C °C °F VHMS
4/12 1 Engine speed r/min rpm rpm 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
2
5 L/B common rail pressure MPa kg/cm psi ENG
2
6 R/B common rail pressure MPa kg/cm psi ENG
5/12 1 Engine speed r/min rpm rpm ENG
2 Ambient temperature °C °C °F VHMS
2
3 Ambient pressure kPa kg/cm 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
6/12 1 Engine speed r/min rpm rpm ENG
2 Ambient temperature °C °C °F VHMS
2
3 Ambient pressure kPa kg/cm psi ENG
4 R/B fuel temperature °C °C °F ENG
2
5 R/B common rail pressure MPa kg/cm psi ENG
2
6 Blow-by pressure MPa kg/cm psi VHMS
7/12 1 Engine speed r/min rpm rpm ENG
2 Hydraulic oil temperature °C °C °F PUMP (2)
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)
6 P2R pump pressure MPa kg/cm2 psi PUMP (1)
PC2000-8 55
SEN02009-05 30 Testing and adjusting
Component in
Page Item PM-clinic display item ISO m inch
charge
8/12 1 Engine speed r/min rpm rpm ENG
2 Hydraulic oil temperature °C °C °F PUMP (2)
2
3 P1F pump pressure MPa kg/cm psi PUMP (1)
2
4 P1R pump pressure MPa kg/cm psi PUMP (1)
2
5 VR1 J/S differential pressure MPa kg/cm psi PUMP (1)
2
6 VL1 J/S differential pressure MPa kg/cm psi PUMP (1)
9/12 1 Engine speed r/min rpm rpm ENG
2 Hydraulic oil temperature °C °C °F PUMP (2)
2
3 P2F pump pressure MPa kg/cm psi PUMP (1)
2
4 P2R pump pressure MPa kg/cm psi PUMP (1)
2
5 VR2 J/S differential pressure MPa kg/cm psi PUMP (1)
2
6 VL2 J/S differential pressure MPa kg/cm psi PUMP (1)
10/12 1 Engine speed r/min rpm rpm ENG
2 Hydraulic oil temperature °C °C °F PUMP (2)
2
3 P1F pump pressure MPa kg/cm psi PUMP (1)
4 P1R pump pressure MPa kg/cm2 psi PUMP (1)
5 P1F pump EPC current mA mA mA PUMP (1)
6 P1R pump EPC current mA mA mA PUMP (1)
11/12 1 Engine speed r/min rpm rpm ENG
2 Hydraulic oil temperature °C °C °F PUMP (2)
2
3 P2F pump pressure MPa kg/cm psi PUMP (1)
2
4 P2R pump pressure MPa kg/cm psi PUMP (1)
5 P2F pump EPC current mA mA mA PUMP (1)
6 P2R pump EPC current mA mA mA PUMP (1)
12/12 1 Engine speed r/min rpm rpm ENG
2 Ambient temperature °C °C °F VHMS
2
3 O/C fan pulley pressure MPa kg/cm psi PUMP (1)
2
4 RAD fan pump pressure MPa kg/cm 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
30 Testing and adjusting SEN02009-05
PC2000-8 57
SEN02009-05
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 09-10
58
SEN02010-05
PC2000-8
PC2000-8 1
SEN02010-05 30 Testing and adjusting
2 PC2000-8
30 Testing and adjusting SEN02010-05
PC2000-8 3
SEN02010-05 30 Testing and adjusting
Important
a Appearance of the setup screen of
the VHMS setting tool depends its
tool.
a When using Ver.3.5.2.1 or older ver-
5. Initial setting of VHMS controller (Ver. 3. 5.
sion (CD-ROM), the setting proce-
2. 1 or older version)
dure shall conform to that described
a This work is done inside the cab (from
in Section 5.
PC).
a When using an update version
a It is prohibited in the initial setting to mod-
(Ver.3.5.2.1 or after), the procedure in
ify the data of service meter [SMR].
Section 6 shall be used.
[Machine Information]
a It is recommended to download the
1) Open [Machine Information] tab.
latest VHMS version from WebCARE
a [Data clear and Set up] menu displays
to update the currently used version.
[Machine Information] tab first.
(Related material: PARTS & SER-
2) Check every data for correctness.
VICE OPERAT ION TIPS SEK N-
5052)
2) Enter the 10-digit service ID to [Service ID].
a Service ID: 7826117000
3) Select [Data clear and Set up] from
[Select Function] item.
4) Click [OK] button to proceed to the setup
screen.
4 PC2000-8
30 Testing and adjusting SEN02010-05
PC2000-8 5
SEN02010-05 30 Testing and adjusting
3) When modifying the setting of [SHORT 5) 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.
6 PC2000-8
30 Testing and adjusting SEN02010-05
PC2000-8 7
SEN02010-05 30 Testing and adjusting
3) When the maintenance mode change 7. Initial setting of VHMS controller (Ver. 3. 5.
screen appears, move the yellow cursor 2. 1 or later version)
onto "99 Use Default Value" using [F3] or a This work is done inside the cab (from PC).
[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.
8 PC2000-8
30 Testing and adjusting SEN02010-05
PC2000-8 9
SEN02010-05 30 Testing and adjusting
8) If there is no problem in the setting dis- 11) Turn the starting switch OFF.
played last, press [Apply] button. Check that the 7-segment LED of the
VHMS controller keeps displaying for sev-
eral seconds and then goes off securely.
9) A screen message will confirm whether or 12) Opening station request of ORBCOMM
not the data before the setting is to be terminal
saved. If the data is not necessary, select Fill in the necessary matters in the paper
[NO]. of “Opening request of ORBCOMM termi-
nal” and send Customer Support Gr. Solu-
tion Div. Komatsu Ltd. by fax or mail.
10 PC2000-8
30 Testing and adjusting SEN02010-05
Note)
It will take one or two weeks to activate after being received this sheet.
ORBCOMM terminal is unable to communicate before activation being completed.
PC2000-8 11
SEN02010-05 30 Testing and adjusting
8. Performing Quick Pm 5) Press the [F1] switch to start the snap shot
a Perform the following procedure in the cab. operation.
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 a Before starting the snap shot opera-
q Swing lock switch: OFF tion, understand the operating proce-
q PCC lock lever: Free dure for the Quick Pm by referring to
3) Set the machine monitor to display the “Operating procedure for Quick Pm”.
service menu. a The data of 48 items are recorded
a For the operating method, see “Spe- and saved for 7 minutes 30 seconds
cial function of machine monitor”. 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.
12 PC2000-8
30 Testing and adjusting SEN02010-05
PC2000-8 13
SEN02010-05 30 Testing and adjusting
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.)
14 PC2000-8
30 Testing and adjusting SEN02010-05
PC2000-8 15
SEN02010-05 30 Testing and adjusting
16 PC2000-8
30 Testing and adjusting SEN02010-05
E-mail: webcare@komatsu.co.jp
PC2000-8 17
SEN02010-05 30 Testing and adjusting
Model name
Confirmation of machine body and Serial No.
1
component nameplates Engine serial No.
VHMS controller serial No.
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?
Initial setting of VHMS controller Is model name identical with machine body? yes no
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
18 PC2000-8
30 Testing and adjusting SEN02010-05
Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
VHMS controller serial No.
ORBCOMM terminal serial No.
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
6 Saving of settings Is LED (7-segment) turned off after data was stored? yes no
PC2000-8 19
SEN02010-05 30 Testing and adjusting
20 PC2000-8
30 Testing and adjusting SEN02010-05
PC2000-8 21
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22 PC2000-8
30 Testing and adjusting SEN02010-05
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.
PC2000-8 23
SEN02010-05 30 Testing and adjusting
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 This work is done inside the cab (from PC).
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.
24 PC2000-8
30 Testing and adjusting SEN02010-05
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.
PC2000-8 25
SEN02010-05 30 Testing and adjusting
E-mail: webcare@komatsu.co.jp
26 PC2000-8
30 Testing and adjusting SEN02010-05
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
PC2000-8 27
SEN02010-05 30 Testing and adjusting
3. Pump controller
1) Remove the controller cover bolts and
controller cover in the operator's cab.
2) Insert or connect troubleshooting T-adapt-
ers in or to connectors CP01, CP02 and
CP03 of pump controller 1.
3) Insert or connect troubleshooting T-adapt-
ers in or to connectors CP04, CP05 and
CP06 of pump controller 2.
4. VHMS controller
1) Open the distribution board cover.
2) Insert or connect troubleshooting T-adapt-
ers in or to connectors CV01, CV02A,
CV02B, CV03A, CV04A and CV04B of the
VHMS controller (1).
28 PC2000-8
30 Testing and adjusting SEN02010-05
Pm-clinic service 1
PC2000-8 29
SEN02010-05 30 Testing and adjusting
30 PC2000-8
30 Testing and adjusting SEN02010-05
PC2000-8 31
SEN02010-05 30 Testing and adjusting
4. Measuring with “PM clinic (2/12)” 6. Measuring with “PM clinic (4/12)”
1) Display “PM clinic (2/12)”. 1) Display “PM clinic (4/12)”.
2) Measure the engine speed, intake air 2) Measure the engine speed, ambient tem-
pressure and exhaust temperature (at the perature, left-bank fuel temperature, right-
front and rear of the right bank and left bank fuel temperature and common rail
bank). pressure (of the right and left banks).
a For the measurement conditions, see a For the measurement conditions, see
the check sheet. the check sheet.
5. Measuring with “PM clinic (3/12)” 7. Measuring with “PM clinic (5/12)”
1) Display “PM clinic (3/12)”. 1) Display “PM clinic (5/12)”.
2) Measure the engine speed, intake air tem- 2) Measure the engine speed, ambient tem-
perature, left-bank common rail pressure, perature, left-bank fuel temperature, left-
left-bank boost pressure and exhaust tem- bank common rail pressure and blow-by
perature (at the front of the left bank). pressure.
a For the measurement conditions, see a For the measurement conditions, see
the check sheet. the check sheet.
32 PC2000-8
30 Testing and adjusting SEN02010-05
8. Measuring with “PM clinic (6/12)” 10. Measuring with “PM clinic (8/12)”
1) Display “PM clinic (6/12)”. 1) Display “PM clinic (8/12)”.
2) Measure the engine speed, ambient tem- 2) Measure the engine speed, hydraulic oil
perature, right-bank fuel temperature, temperature, P1F pump pressure, P1R
right-bank common rail pressure and pump pressure, VR1 J/S differential pres-
blow-by pressure. sure and VL1 J/S differential pressure.
a For the measurement conditions, see a For the measurement conditions, see
the check sheet. the check sheet.
PC2000-8 33
SEN02010-05 30 Testing and adjusting
12. Measuring with “PM clinic (10/12)” 14. Measuring with “PM clinic (12/12)”
1) Display “PM clinic (10/12)”. 1) Display “PM clinic (12/12)”.
2) Measure the engine speed, hydraulic oil 2) Measure the engine speed, ambient tem-
temperature, P1F pump pressure, P1R perature, fan pump pressure (O/C), fan
pump pressure, P1F pump control EPC pump pressure (RAD), fan pump control
current and P1R pump control EPC cur- EPC (RAD) current and fan pump control
rent. EPC (O/C) current
a For the measurement conditions, see a For the measurement conditions, see
the check sheet. the check sheet.
34 PC2000-8
30 Testing and adjusting SEN02010-05
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.
PC2000-8 35
SEN02010-05 30 Testing and adjusting
3. Change of display of machine monitor 2) Operate the switches and levers at each
1) Set the machine monitor to display the execution time according to the “Operat-
service menu selection screen. ing procedure for quick PM clinic” shown
a See “Functions and operation of in the following table.
machine monitor”. a The execution times are displayed on
2) Select “Snap shot”. 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.
36 PC2000-8
30 Testing and adjusting SEN02010-05
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.)
PC2000-8 37
SEN02010-05 30 Testing and adjusting
38 PC2000-8
30 Testing and adjusting SEN02010-05
PC2000-8 39
SEN02010-05 30 Testing and adjusting
Whole work equipment Work equipment pos- bucket tooth tip {Max. 650} {Max. 1000}
ture: Boom and arm in Max. 60 Max. 90
Boom cylinder level, bucket curled, Cylinder retraction
mm/15 {Max. 35} {Max. 50}
rated load on work
equipment {no load} min Max. 165 Max. 250
Arm cylinder Cylinder extension
Hydraulic oil tempera- {Max. 70} {Max. 105}
ture: 45 – 55ºC Max. 50 Max. 75
Bucket cylinder Cylinder retraction
{Max. 15} {Max. 25}
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 mA P2 : 615 – 735 P2 : 615 – 735
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 28.7 – 30.7 27.7 – 30.7
(Normal) {293 – 313} {283 – 313}
Boom: Raise relief 31.5 – 33.5 30.5 – 33.5
(Heavy lift ON) {322 – 342} {312 – 342}
28.7 – 30.7 27.7 – 30.7
Arm: In relief
5-4 {293 – 313} {283 – 313}
P1F pump pressure 28.7 – 30.7 27.7 – 30.7
Arm: Out relief
{293 – 313} {283 – 313}
28.7 – 30.7 27.7 – 30.7
Bucket: Curl relief
{293 – 313} {283 – 313}
5 Hydraulic system
40 PC2000-8
30 Testing and adjusting SEN02010-05
Fan speed (Radiator) temperature: 45 – 55ºC Neutral 55ºC : 1050 – 1150 55ºC : 1050 – 1150
Mode: P
rpm
5-11 Engine: Full throttle Control lever: STD : 710 – 810 STD : 710 – 810
Fan speed (Oil cooler) Fan: 100% speed mode Neutral 55ºC : 1050 – 1150 55ºC : 1050 – 1150
Auto-decelerator: OFF
Mode: P
5-12
Engine: Full throttle
Hydraulic oil Bucket: Dump relief ºC Max. 100ºC Max. 100ºC
Fan: 100% speed mode
temperature
Auto-decelerator: OFF
Memo: Enter phenomena and information you noticed during today's check.
PC2000-8 41
SEN02010-05 30 Testing and adjusting
42 PC2000-8
30 Testing and adjusting SEN02010-05
PC2000-8 43
SEN02010-05 30 Testing and adjusting
Standard value for Service limit value Measurement result Accepted Rejected
Measurement items Condition Unit
new machine F engine R engine
5-1 Control lever: Neu- 3.24 – 3.73 3.04 – 3.73
Control pressure (PPC tral {33 – 38} {31 – 38}
basic pressure)
Control lever: Neu- Min. 1.28 MPa Min. 1.28 MPa
tral {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: Neu-
tral 160 – 280 160 – 280
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 MPa 28.7 – 30.7 27.7 – 30.7
(Normal) {kg/cm2} {293 – 313} {283 – 313}
Boom: Raise relief 31.5 – 33.5 30.5 – 33.5
(Heavy lift ON) {322 – 342} {312 – 342}
5 Hydraulic system
44 PC2000-8
30 Testing and adjusting SEN02010-05
Memo: Enter phenomena and information you noticed during today's check.
PC2000-8 45
SEN02010-05 30 Testing and adjusting
46 PC2000-8
30 Testing and adjusting SEN02010-05
PC2000-8 47
SEN02010-05
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 03-11
48
SEN02011-02
PC2000-8
40 Troubleshooting 1
Failure code table and fuse locations
Failure code table ........................................................................................................................................... 2
Before carrying out troubleshooting of electrical system ................................................................................ 9
PC2000-8 1
SEN02011-02 40 Troubleshooting
2 PC2000-8
40 Troubleshooting SEN02011-02
PC2000-8 3
SEN02011-02 40 Troubleshooting
4 PC2000-8
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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.
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14 PC2000-8
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PC2000-8 15
SEN02011-02
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
16
SEN02012-05
PC2000-8
40 Troubleshooting 1
General information on troubleshooting
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- branch box and T- branch adapter table ................................................................................................... 45
PC2000-8 1
SEN02012-05 40 Troubleshooting
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, an important point is of course to under-
stand the structure and function. However, a shortcut 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.
2 PC2000-8
40 Troubleshooting SEN02012-05
PC2000-8 3
SEN02012-05 40 Troubleshooting
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
40 Troubleshooting SEN02012-05
Troubleshooting procedures
If a problem occurs on the machine, or if it is felt that there is a problem, carry out troubleshooting as follows.
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
SEN02012-05 40 Troubleshooting
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
4 Starting performance is poor S-1
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 does not pick up smoothly S-3
9 Engine stops during operations S-4
10 Engine does not rotate smoothly S-5
11 Engine lacks output (or lacks power) S-6
12 Exhaust smoke is black (incomplete combustion) S-7
13 Oil consumption is excessive (or exhaust smoke is blue) S-8
14 Oil becomes contaminated quickly S-9
15 Fuel consumption is excessive S-10
16 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
17 Oil pressure drops S-12
18 Oil level rises (Entry of coolant or fuel) S-13
19 Coolant temperature becomes too high (overheating) S-14
20 Abnormal noise is made S-15
21 Vibration is excessive S-16
22 Auto-decelerator does not operate E-4
23 Automatic warm-up system does not operate E-5
24 Pre heater does not work E-6
Failure related to work equipment, swing and travel
25 Speed or power of whole work equipment, travel, and swing is low H-1
26 Engine speed lowers remarkably or engine stalls H-2
Whole work equipment, swing operation and machine travel operation
27 E-7 H-3
are disabled
28 Abnormal noise comes from around hydraulic pump H-4
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40 Troubleshooting SEN02012-05
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Work equipment-related failure
29 Speed or power of boom is low H-5
30 Speed or power of arm is low H-6
31 Speed or power of bucket is low H-7
32 Bottom dump speed or power is lower (Loading shovel specification) H-29
33 Boom does not move H-8
34 Arm does not move H-9
35 Bucket does not move H-10
36 Bottom dump cylinder does not move (Loading shovel specification) H-30
37 Hydraulic drift of work equipment is large H-11
38 Time lag of work equipment is large H-12
39 Machine push-up function does not work or is not reset E-8 H-14
40 Heavy lift function does not work or is not reset H-13
41 Boom shock less function does not work or is not reset E-9 H-15
Travel-related failure
42 Machine gradually deviates during traveling H-16
43 Machine deviates excessively when started to travel H-17
44 Machine deviates excessively during multiple operations H-18
45 Travel speed or power is low H-19
46 Travel system does not move (only one side) H-20
Swing-related failure
47 Upper structure does not swing H-21
48 Swing speed or acceleration is low H-22
In compound operation of work equipment, swing speed or accelera-
49 H-23
tion is low
50 Upper structure overruns remarkably when it stops swinging H-24
51 Large shock is made when upper structure stops swinging H-25
Large abnormal sound comes from when upper structure stops swing-
52 H-26
ing
53 Hydraulic drift of work equipment is large in swing operation H-27
Fan rotation is abnormal (large noise or vibration of fans, or fan over-
54 H-28
heating)
Machine monitor-related failure (Operator's Menu: ordinary display)
55 When starting switch turned ON, machine monitor displays nothing E-1
When starting switch turned ON (before starting engine), basic check
56 E-2
item lights up
57 Machine monitor does not display some items E-10
Contents of display by machine monitor are different from applicable
58 E-11
machine
PC2000-8 7
SEN02012-05 40 Troubleshooting
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
59 Fuel level monitor lights up in red while engine is running E-12
60 Hydraulic oil temperature gauge does not indicate normally E-13
61 Fuel level gauge does not indicate normally E-14
62 Swing lock monitor does not indicate normally E-15
Machine monitor display anything even when operated on monitor
63 E-16
switch section
64 Wiper does not work E-17
Monitor panel-related failure (Service Menu: Special Function Display)
65 Monitoring function does not display "Travel" normally E-18
Other failure
66 Travel alarm does not sound E-19
67 All of room lamp, head lamp and working lamp do not light up E-20
68 Air conditioner does not work E-21
69 Step light does not light up or goes off E-22
8 PC2000-8
40 Troubleshooting SEN02012-05
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
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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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
PC2000-8 45
SEN02012-05 40 Troubleshooting
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
46 PC2000-8
40 Troubleshooting SEN02012-05
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
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 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
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
795-799-5470 Cable for engine (HPI-T2) 3 — q
795-799-5480 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190* 3 1,2,3L q q
Commonrail pressure
Socket for engine (CRI-T3)
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
Socket for engine (CRI-T3)
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
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
PC2000-8 47
SEN02012-05
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 05-10
48
SEN02096-03
PC2000-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 1
Failure code [0410KA] Fuel LV. Sensor Failure .............................................................................................. 4
Failure code [0410KB] Fuel LV. Sensor Failure .............................................................................................. 6
Failure code [6014NX] Hydraulic Oil Filter Clogging
(or change of VHMS-LED display from n5 to 51)........................................................................................ 8
Failure code [8800ZG] Auto grease abnormally ............................................................................................. 9
Failure code [7@HAZL] VR1/P1F Relief Press Abnormality ........................................................................ 10
Failure code [7@HBZL] VL1/P1R Relief Press Abnormality..........................................................................11
Failure code [7@HCZL] VR2/P2F Relief Press Abnormality ........................................................................ 12
Failure code [7@HDZL] VL2/P2R Relief Press Abnormality ........................................................................ 14
Failure code [AA10NX] Aircleaner Clogging ................................................................................................. 16
Failure code [AB00KE] Charge Voltage Low ................................................................................................ 18
Failure code [aB00KE] Low Upper ALR Charge Voltage
(or change of VHMS-LED display from n9 to 11)...................................................................................... 20
Failure code [B@BAZG] Eng. Oil Press. Low............................................................................................... 22
Failure code [B@BAZK] Eng. Oil Level Low................................................................................................. 24
Failure code [B@BCNS] Eng. Water Overheat............................................................................................. 26
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Failure code [aB00KE] Low Upper ALR Charge Voltage (or change of
VHMS-LED display from n9 to 11) 1
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
• None in particular.
controller
Problem that
appears on • If machine is operated as it is, battery may not be charged.
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: n9 o 11 (codes are displayed by 2 digits)
20 PC2000-8
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a Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Defective machine CM02 Engine oil level Voltage
4
monitor
Between (2) – Normal level Max. 1 V
chassis ground Below normal level 20 – 30 V
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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
• None in particular.
controller
Problem that
appears on • If machine is operated as it is, hydraulic components may be damaged.
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 52 (codes are displayed by 2 digits)
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SEN02096-03
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
68
SEN02097-02
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40 Troubleshooting 1
Troubleshooting by failure code, Part 2
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
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Circuit diagram related to sensor power source (2) (At right bank)
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PC2000-8 25
SEN02097-02 40 Troubleshooting
26 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 27
SEN02097-02 40 Troubleshooting
28 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 29
SEN02097-02 40 Troubleshooting
30 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 31
SEN02097-02 40 Troubleshooting
32 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 33
SEN02097-02 40 Troubleshooting
34 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 35
SEN02097-02 40 Troubleshooting
36 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 37
SEN02097-02 40 Troubleshooting
38 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 39
SEN02097-02 40 Troubleshooting
40 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 41
SEN02097-02 40 Troubleshooting
42 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 43
SEN02097-02 40 Troubleshooting
44 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 45
SEN02097-02 40 Troubleshooting
46 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 47
SEN02097-02 40 Troubleshooting
48 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 49
SEN02097-02 40 Troubleshooting
50 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 51
SEN02097-02 40 Troubleshooting
52 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 53
SEN02097-02 40 Troubleshooting
54 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 55
SEN02097-02 40 Troubleshooting
56 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 57
SEN02097-02 40 Troubleshooting
58 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 59
SEN02097-02 40 Troubleshooting
60 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 61
SEN02097-02 40 Troubleshooting
62 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 63
SEN02097-02 40 Troubleshooting
64 PC2000-8
40 Troubleshooting SEN02097-02
PC2000-8 65
SEN02097-02
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
66
SEN02098-02
PC2000-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 3
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
Failure code [CB731] Eng Bkup Speed Sens Phase Error ........................................................................... 27
PC2000-8 1
SEN02098-02 40 Troubleshooting
2 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 3
SEN02098-02 40 Troubleshooting
4 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 5
SEN02098-02 40 Troubleshooting
6 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 7
SEN02098-02 40 Troubleshooting
8 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 9
SEN02098-02 40 Troubleshooting
10 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 11
SEN02098-02 40 Troubleshooting
12 PC2000-8
40 Troubleshooting SEN02098-02
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
SEN02098-02 40 Troubleshooting
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
*5 Equivalent to rating MPa
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
*9 Low idle °C — — —
(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 — — —
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
40 Troubleshooting SEN02098-02
PC2000-8 15
SEN02098-02 40 Troubleshooting
16 PC2000-8
40 Troubleshooting SEN02098-02
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
SEN02098-02 40 Troubleshooting
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 Equivalent to rating MPa
4 rail pressure
Fuel pressure in
*5 Equivalent to rating MPa
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
*9 Low idle °C — — —
(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 — — —
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
40 Troubleshooting SEN02098-02
PC2000-8 19
SEN02098-02 40 Troubleshooting
20 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 21
SEN02098-02 40 Troubleshooting
22 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 23
SEN02098-02 40 Troubleshooting
24 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 25
SEN02098-02 40 Troubleshooting
26 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 27
SEN02098-02 40 Troubleshooting
28 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 29
SEN02098-02 40 Troubleshooting
30 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 31
SEN02098-02 40 Troubleshooting
32 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 33
SEN02098-02 40 Troubleshooting
34 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 35
SEN02098-02 40 Troubleshooting
36 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 37
SEN02098-02 40 Troubleshooting
38 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 39
SEN02098-02 40 Troubleshooting
40 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 41
SEN02098-02 40 Troubleshooting
42 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 43
SEN02098-02 40 Troubleshooting
44 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 45
SEN02098-02 40 Troubleshooting
46 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 47
SEN02098-02 40 Troubleshooting
48 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 49
SEN02098-02 40 Troubleshooting
50 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 51
SEN02098-02 40 Troubleshooting
52 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 53
SEN02098-02 40 Troubleshooting
54 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 55
SEN02098-02 40 Troubleshooting
56 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 57
SEN02098-02 40 Troubleshooting
User code Failure code Grid Heater Relay Volt Low Error
Trouble
E15 CA2555 (Engine controller system)
Contents of
• Voltage low error was detected in grid heater relay circuit.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related
information
58 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 59
SEN02098-02 40 Troubleshooting
User code Failure code Grid Heater Relay Volt High Error
Trouble
E15 CA2556 (Engine controller system)
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
60 PC2000-8
40 Troubleshooting SEN02098-02
PC2000-8 61
SEN02098-02
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
62
SEN02099-03
PC2000-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 4
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
PC2000-8 1
SEN02099-03 40 Troubleshooting
2 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 3
SEN02099-03 40 Troubleshooting
4 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 5
SEN02099-03 40 Troubleshooting
6 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 7
SEN02099-03 40 Troubleshooting
8 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 9
SEN02099-03 40 Troubleshooting
10 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 11
SEN02099-03 40 Troubleshooting
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
40 Troubleshooting SEN02099-03
PC2000-8 13
SEN02099-03 40 Troubleshooting
14 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 15
SEN02099-03 40 Troubleshooting
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
40 Troubleshooting SEN02099-03
PC2000-8 17
SEN02099-03 40 Troubleshooting
18 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 19
SEN02099-03 40 Troubleshooting
20 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 21
SEN02099-03 40 Troubleshooting
22 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 23
SEN02099-03 40 Troubleshooting
24 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 25
SEN02099-03 40 Troubleshooting
26 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 27
SEN02099-03 40 Troubleshooting
28 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 29
SEN02099-03 40 Troubleshooting
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
40 Troubleshooting SEN02099-03
PC2000-8 31
SEN02099-03 40 Troubleshooting
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
40 Troubleshooting SEN02099-03
PC2000-8 33
SEN02099-03 40 Troubleshooting
34 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 35
SEN02099-03 40 Troubleshooting
36 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 37
SEN02099-03 40 Troubleshooting
38 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 39
SEN02099-03 40 Troubleshooting
40 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 41
SEN02099-03 40 Troubleshooting
42 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 43
SEN02099-03 40 Troubleshooting
44 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 45
SEN02099-03 40 Troubleshooting
Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMS-
LED display from n9 to 04) 1
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
• None in particular.
controller
Problem that
appears on • The sensor value may not be displayed normally.
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: n9 o 04 (codes are displayed by 2 digits)
46 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 47
SEN02099-03 40 Troubleshooting
Failure code [DBB6KP] VHMS 24V source sys Error (or change of
VHMS-LED display from n9 to 02) 1
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
• None in particular.
controller
Problem that
appears on • The sensor value may not be displayed normally.
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: n9 o 02 (codes are displayed by 2 digits)
48 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 49
SEN02099-03 40 Troubleshooting
50 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 51
SEN02099-03 40 Troubleshooting
Failure code [DGE5KX] Ambient Air Temp Sensor Failure (or change of
VHMS-LED display from n4 to 01) 1
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
• None in particular.
controller
Problem that
appears on •
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: n4 o 01 (codes are displayed by 2 digits)
52 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 53
SEN02099-03 40 Troubleshooting
54 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 55
SEN02099-03 40 Troubleshooting
Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMS-
LED display from n5 to 01) 1
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
• None in particular.
controller
Problem that
appears on • The snapshot data downloaded to the PC is not displayed normally.
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 01 (codes are displayed by 2 digits)
information
• PTO oil temperature can be checked by downloading data to PC after the snapshot.
56 PC2000-8
40 Troubleshooting SEN02099-03
PC2000-8 57
SEN02099-03
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
58
SEN02100-03
PC2000-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 5
Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure
(or change of VHMS-LED display from n3 to 12)........................................................................................ 4
Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure
(or change of VHMS-LED display from n3 to 22)........................................................................................ 6
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
(or change of VHMS-LED display from n3 to 21)...................................................................................... 10
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
(or change of VHMS-LED display from n3 to 26)...................................................................................... 14
Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure
(or change of VHMS-LED display from n3 to 23)...................................................................................... 16
Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure
(or change of VHMS-LED display from n3 to 26)...................................................................................... 18
PC2000-8 1
SEN02100-03 40 Troubleshooting
2 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 3
SEN02100-03 40 Troubleshooting
Failure code [DGT5KA] Exhaust Temp. Sensor LBF Failure (or change of
VHMS-LED display from n3 to 12) 1
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
• None in particular.
controller
Problem that
appears on • The snapshot data downloaded to the PC is not displayed normally.
machine
• Failure codes of VHMS system are not recorded on the trouble data of the machine monitor.
Related
• VHMS controller 7-segment LED display: n3 o 12 (codes are displayed by 2 digits)
information
• Exhaust gas temperature can be checked by downloading data to PC after the snapshot.
4 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 5
SEN02100-03 40 Troubleshooting
Failure code [dGT5KA] Exhaust Temp. Sensor LBR Failure (or change of
VHMS-LED display from n3 to 22) 1
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
• None in particular.
controller
Problem that
appears on • The snapshot data downloaded to the PC is not displayed normally.
machine
• Failure codes of VHMS system are not recorded on the trouble data of the machine monitor.
Related
• VHMS controller 7-segment LED display: n3 o 22 (codes are displayed by 2 digits)
information
• Exhaust gas temperature can be checked by downloading data to PC after the snapshot.
6 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 7
SEN02100-03 40 Troubleshooting
Failure code [DGT5KB] Exhaust Temp. Sensor LBF Failure (or change of
VHMS-LED display from n3 to 11) 1
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
• None in particular.
controller
Problem that
appears on • The snapshot data downloaded to the PC is not displayed normally.
machine
• Failure codes of VHMS system are not recorded on the trouble data of the machine monitor.
Related
• VHMS controller 7-segment LED display: n3 o 11 (codes are displayed by 2 digits)
information
• Exhaust gas temperature can be checked by downloading data to PC after the snapshot.
8 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 9
SEN02100-03 40 Troubleshooting
Failure code [dGT5KB] Exhaust Temp. Sensor LBR Failure (or change of
VHMS-LED display from n3 to 21) 1
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
• None in particular.
controller
Problem that
appears on • The snapshot data downloaded to the PC is not displayed normally.
machine
• Failure codes of VHMS system are not recorded on the trouble data of the machine monitor.
Related
• VHMS controller 7-segment LED display: n3 o 21 (codes are displayed by 2 digits)
information
• Exhaust gas temperature can be checked by downloading data to PC after the snapshot.
10 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 11
SEN02100-03 40 Troubleshooting
Failure code [DGT6KA] Exhaust Temp. Sensor RBF Failure (or change of
VHMS-LED display from n3 to 24) 1
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
• None in particular.
controller
Problem that
appears on • The snapshot data downloaded to the PC is not displayed normally.
machine
• Failure codes of VHMS system are not recorded on the trouble data of the machine monitor.
Related
• VHMS controller 7-segment LED display: n3 o 24 (codes are displayed by 2 digits)
information
• Exhaust gas temperature can be checked by downloading data to PC after the snapshot.
12 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 13
SEN02100-03 40 Troubleshooting
Failure code [dGT6KA] Exhaust Temp. Sensor RBR Failure (or change of
VHMS-LED display from n3 to 26) 1
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
• None in particular.
controller
Problem that
appears on • The snapshot data downloaded to the PC is not displayed normally.
machine
• Failure codes of VHMS system are not recorded on the trouble data of the machine monitor.
Related
• VHMS controller 7-segment LED display: n3 o 26 (codes are displayed by 2 digits)
information
• Exhaust gas temperature can be checked by downloading data to PC after the snapshot.
14 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 15
SEN02100-03 40 Troubleshooting
Failure code [DGT6KB] Exhaust Temp. Sensor RBF Failure (or change of
VHMS-LED display from n3 to 23) 1
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
• None in particular.
controller
Problem that
appears on • The snapshot data downloaded to the PC is not displayed normally.
machine
• Failure codes of VHMS system are not recorded on the trouble data of the machine monitor.
Related
• VHMS controller 7-segment LED display: n3 o 23 (codes are displayed by 2 digits)
information
• Exhaust gas temperature can be checked by downloading data to PC after the snapshot.
16 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 17
SEN02100-03 40 Troubleshooting
Failure code [dGT6KB] Exhaust Temp. Sensor RBR Failure (or change of
VHMS-LED display from n3 to 26) 1
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
• None in particular.
controller
Problem that
appears on • The snapshot data downloaded to the PC is not displayed normally.
machine
• Failure codes of VHMS system are not recorded on the trouble data of the machine monitor.
Related
• VHMS controller 7-segment LED display: n3 o 26 (codes are displayed by 2 digits)
information
• Exhaust gas temperature can be checked by downloading data to PC after the snapshot.
18 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 19
SEN02100-03 40 Troubleshooting
20 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 21
SEN02100-03 40 Troubleshooting
22 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 23
SEN02100-03 40 Troubleshooting
24 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 25
SEN02100-03 40 Troubleshooting
26 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 27
SEN02100-03 40 Troubleshooting
28 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 29
SEN02100-03 40 Troubleshooting
30 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 31
SEN02100-03 40 Troubleshooting
Failure code [DHH2KA] Hydraulic oil filter Sensor Failure (or change of
VHMS-LED display from n5 to 53) 1
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
• None in particular.
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 “53” (codes are displayed by 2 digits)
32 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 33
SEN02100-03 40 Troubleshooting
34 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 35
SEN02100-03 40 Troubleshooting
36 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 37
SEN02100-03 40 Troubleshooting
38 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 39
SEN02100-03 40 Troubleshooting
40 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 41
SEN02100-03 40 Troubleshooting
42 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 43
SEN02100-03 40 Troubleshooting
44 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 45
SEN02100-03 40 Troubleshooting
46 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 47
SEN02100-03 40 Troubleshooting
48 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 49
SEN02100-03 40 Troubleshooting
50 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 51
SEN02100-03 40 Troubleshooting
52 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 53
SEN02100-03 40 Troubleshooting
54 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 55
SEN02100-03 40 Troubleshooting
56 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 57
SEN02100-03 40 Troubleshooting
58 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 59
SEN02100-03 40 Troubleshooting
60 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 61
SEN02100-03 40 Troubleshooting
62 PC2000-8
40 Troubleshooting SEN02100-03
PC2000-8 63
SEN02100-03
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 05-10
64
SEN02101-02
PC2000-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 6
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 Motor (RAD) 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
PC2000-8 1
SEN02101-02 40 Troubleshooting
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
40 Troubleshooting SEN02101-02
PC2000-8 3
SEN02101-02 40 Troubleshooting
4 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 5
SEN02101-02 40 Troubleshooting
6 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 7
SEN02101-02 40 Troubleshooting
8 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 9
SEN02101-02 40 Troubleshooting
10 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 11
SEN02101-02 40 Troubleshooting
12 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 13
SEN02101-02 40 Troubleshooting
14 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 15
SEN02101-02 40 Troubleshooting
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
a Prepare with starting switch OFF, then carry out troubleshooting without
Disconnection of wiring turning starting switch ON.
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
connector) Wiring harness between V03 (female) (1) and Resistance
standard value 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
(5) – V07 (female) (1) and grounding
a Prepare with starting switch OFF, then carry out troubleshooting without
Pump controller 2 turning starting switch ON.
4
defective CP06 (female) Resistance value
Between (5) – (13) 20 – 60 z
16 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 17
SEN02101-02 40 Troubleshooting
Possible Grounding fault of wir- a Prepare with starting switch OFF, then carry out troubleshooting without
ing harness turning starting switch ON.
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
a Prepare with starting switch OFF, then start engine and carry out trou-
bleshooting.
CP06 Control lever Voltage
Pump controller 2
3 NEUTRAL Max. 1 V
defective
Between (5) – (13) Both tracks operation +
Work equipment opera- 20 – 30 V
tion
18 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 19
SEN02101-02 40 Troubleshooting
20 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 21
SEN02101-02 40 Troubleshooting
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)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
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.
22 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 23
SEN02101-02 40 Troubleshooting
24 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 25
SEN02101-02 40 Troubleshooting
26 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 27
SEN02101-02 40 Troubleshooting
28 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 29
SEN02101-02 40 Troubleshooting
30 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 31
SEN02101-02 40 Troubleshooting
32 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 33
SEN02101-02 40 Troubleshooting
34 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 35
SEN02101-02 40 Troubleshooting
36 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 37
SEN02101-02 40 Troubleshooting
38 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 39
SEN02101-02 40 Troubleshooting
40 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 41
SEN02101-02 40 Troubleshooting
42 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 43
SEN02101-02 40 Troubleshooting
44 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 45
SEN02101-02 40 Troubleshooting
46 PC2000-8
40 Troubleshooting SEN02101-02
PC2000-8 47
SEN02101-02 40 Troubleshooting
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
Action of • None in particular. (Since no current flows, solenoid does not operate.)
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
the monitoring function.
information
(Monitoring code: 02300 Solenoid 3)
48 PC2000-8
40 Troubleshooting SEN02101-02
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.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
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
the monitoring function.
information
(Monitoring code: 02302 Solenoid 3)
PC2000-8 49
SEN02101-02
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
50
SEN02102-01
PC2000-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 7
Failure code [DWN5KA] Fan(RAD) Pump EPC Sol Open Circuit................................................................... 3
Failure code [DWN5KB] Fan(RAD) Pump EPC Sol Short Circuit ................................................................... 4
Failure code [DWNCKA] Fan(O/C) Pump EPC Sol Open Circuit ................................................................... 5
Failure code [DWNCKB] Fan(O/C) Pump EPC Sol Short Circuit ................................................................... 6
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 (or change of VHMS-LED display from n3 to 38)............... 32
PC2000-8 1
SEN02102-01 40 Troubleshooting
2 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 3
SEN02102-01 40 Troubleshooting
4 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 5
SEN02102-01 40 Troubleshooting
6 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 7
SEN02102-01 40 Troubleshooting
8 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 9
SEN02102-01 40 Troubleshooting
10 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 11
SEN02102-01 40 Troubleshooting
12 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 13
SEN02102-01 40 Troubleshooting
14 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 15
SEN02102-01 40 Troubleshooting
16 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 17
SEN02102-01 40 Troubleshooting
18 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 19
SEN02102-01 40 Troubleshooting
20 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 21
SEN02102-01 40 Troubleshooting
22 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 23
SEN02102-01 40 Troubleshooting
24 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 25
SEN02102-01 40 Troubleshooting
26 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 27
SEN02102-01 40 Troubleshooting
28 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 29
SEN02102-01 40 Troubleshooting
30 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 31
SEN02102-01 40 Troubleshooting
32 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 33
SEN02102-01 40 Troubleshooting
Failure code [F@BYNR] Very High LBF CYL Exhaust Temp (or change of
VHMS-LED display from n3 to 62) 1
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
• None in particular.
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 62 (displays the code 2 characters by 2).
information
• The exhaust temperature can be checked by downloading the data to a personal computer after
performing the snap shot operation.
34 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 35
SEN02102-01 40 Troubleshooting
Failure code [f@BYNR] Very High LBR CYL Exhaust Temp (or change of
VHMS-LED display from n3 to 72) 1
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
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
• None in particular.
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 72 (displays the code 2 characters by
information 2).
• The exhaust temperature can be checked by downloading the data to a personal computer after
performing the snap shot operation.
36 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 37
SEN02102-01 40 Troubleshooting
Failure code [F@BYNS] High LBF CYL Exhaust Temp (or change of
VHMS-LED display from n3 to 61) 1
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
exceeded exhaust temperature limit line 1 for 20 seconds.
Contents of
(Exhaust temperature limit line 1: The straight line connecting 700°C point in the speed range
trouble
above the rated output speed and 750°C point in the speed range below the maximum torque
speed)
Action of
• None in particular.
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 61 (displays the code 2 characters by 2).
information
• The exhaust temperature can be checked by downloading the data to a personal computer after
performing the snap shot operation.
38 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 39
SEN02102-01 40 Troubleshooting
Failure code [f@BYNS] High LBR CYL Exhaust Temp (or change of
VHMS-LED display from n3 to 71) 1
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
exceeded exhaust temperature limit line 1 for 20 seconds.
Contents of
(Exhaust temperature limit line 1: The straight line connecting 700°C point in the speed range
trouble
above the rated output speed and 750°C point in the speed range below the maximum torque
speed)
Action of
• None in particular.
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 71 (displays the code 2 characters by
information 2).
• The exhaust temperature can be checked by downloading the data to a personal computer after
performing the snap shot operation.
40 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 41
SEN02102-01 40 Troubleshooting
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
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
• None in particular.
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 82 (displays the code 2 characters by 2).
information
• The exhaust temperature can be checked by downloading the data to a personal computer after
performing the snap shot operation.
42 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 43
SEN02102-01 40 Troubleshooting
Failure code [f@BZNR] Very High RBR CYL Exhaust Temp (or change of
VHMS-LED display from n3 to 92) 1
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
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
• None in particular.
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 92 (displays the code 2 characters by
information 2).
• The exhaust temperature can be checked by downloading the data to a personal computer after
performing the snap shot operation.
44 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 45
SEN02102-01 40 Troubleshooting
Failure code [F@BZNS] High RBF CYL Exhaust Temp (or change of
VHMS-LED display from n3 to 81) 1
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
exceeded exhaust temperature limit line 1 for 20 seconds.
Contents of
(Exhaust temperature limit line 1: The straight line connecting 700°C point in the speed range
trouble
above the rated output speed and 750°C point in the speed range below the maximum torque
speed)
Action of
• None in particular.
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 81 (displays the code 2 characters by 2).
information
• The exhaust temperature can be checked by downloading the data to a personal computer after
performing the snap shot operation.
46 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 47
SEN02102-01 40 Troubleshooting
Failure code [f@BZNS] High RBR CYL Exhaust Temp (or change of
VHMS-LED display from n3 to 91) 1
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
exceeded exhaust temperature limit line 1 for 20 seconds.
Contents of
(Exhaust temperature limit line 1: The straight line connecting 700°C point in the speed range
trouble
above the rated output speed and 750°C point in the speed range below the maximum torque
speed)
Action of
• None in particular.
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 91 (displays the code 2 characters by 2).
information
• The exhaust temperature can be checked by downloading the data to a personal computer after
performing the snap shot operation.
48 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 49
SEN02102-01 40 Troubleshooting
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
• None in particular (Provides the error display alone)
controller
Problem that
appears on • If machine is operated as it is, hydraulic components may be damaged.
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)
50 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 51
SEN02102-01 40 Troubleshooting
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
• None in particular (Provides the error display alone)
controller
Problem that
appears on • If machine is operated as it is, hydraulic components may be damaged.
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)
52 PC2000-8
40 Troubleshooting SEN02102-01
PC2000-8 53
SEN02102-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 08-08 (01)
54
SEN02103-02
PC2000-8
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode)
Before carrying out troubleshooting of electrical system ................................................................................ 3
Contents of troubleshooting table ................................................................................................................. 10
E-1 When starting switch is turned ON, machine monitor displays nothing.................................................. 12
E-2 When starting switch turned ON (before starting engine), basic check item lights up............................ 14
E-3 Engine does not start (Engine does not turn) ......................................................................................... 16
E-4 Auto-decelerator does not operate......................................................................................................... 20
E-5 Automatic warm-up system does not operate ........................................................................................ 21
E-6 Preheater does not work ........................................................................................................................ 22
E-7 Whole work equipment, swing operation and machine travel operation are disabled............................ 24
E-8 Machine push-up function does not work............................................................................................... 26
E-9 Boom shockless function cannot be released ........................................................................................ 28
E-10 Machine monitor does not display some items .................................................................................... 30
E-11 Contents of display by machine monitor are different from applicable machine................................... 31
E-12 Fuel level monitor lights up in red while engine is running ................................................................... 32
PC2000-8 1
SEN02103-02 40 Troubleshooting
2 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 3
SEN02103-02 40 Troubleshooting
4 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 5
SEN02103-02 40 Troubleshooting
6 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 7
SEN02103-02 40 Troubleshooting
8 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 9
SEN02103-02 40 Troubleshooting
<Described contents>
• Standard value when normal required to judge the possible
cause
1 • Remarks required to judge whether any cause is right or not
10 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 11
SEN02103-02 40 Troubleshooting
12 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 13
SEN02103-02 40 Troubleshooting
14 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 15
SEN02103-02 40 Troubleshooting
16 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 17
SEN02103-02 40 Troubleshooting
18 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 19
SEN02103-02 40 Troubleshooting
20 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 21
SEN02103-02 40 Troubleshooting
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
22 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 23
SEN02103-02 40 Troubleshooting
24 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 25
SEN02103-02 40 Troubleshooting
26 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 27
SEN02103-02 40 Troubleshooting
28 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 29
SEN02103-02 40 Troubleshooting
30 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 31
SEN02103-02 40 Troubleshooting
32 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 33
SEN02103-02 40 Troubleshooting
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.
34 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 35
SEN02103-02 40 Troubleshooting
36 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 37
SEN02103-02 40 Troubleshooting
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
Trouble (3) • When heavy lift switch is operated, heavy lift is not displayed.
Related
–
information
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
38 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 39
SEN02103-02 40 Troubleshooting
40 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 41
SEN02103-02 40 Troubleshooting
Trouble • Wiper does not work. (2) Lower wiper does not work.
• If failure code [DY20MA] 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)
42 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 43
SEN02103-02 40 Troubleshooting
44 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 45
SEN02103-02 40 Troubleshooting
46 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 47
SEN02103-02 40 Troubleshooting
48 PC2000-8
40 Troubleshooting SEN02103-02
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
PC2000-8 49
SEN02103-02 40 Troubleshooting
50 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 51
SEN02103-02 40 Troubleshooting
52 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 53
SEN02103-02 40 Troubleshooting
54 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 55
SEN02103-02 40 Troubleshooting
56 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 57
SEN02103-02 40 Troubleshooting
58 PC2000-8
40 Troubleshooting SEN02103-02
PC2000-8 59
SEN02103-02
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 08-08 (01)
60
SEN02104-03
PC2000-8
40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
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
PC2000-8 1
SEN02104-03 40 Troubleshooting
2 PC2000-8
40 Troubleshooting SEN02104-03
a For the backhoe specification, the bottom dump valves of L1 and L2 are “Unused”.
PC2000-8 3
SEN02104-03 40 Troubleshooting
4 PC2000-8
40 Troubleshooting SEN02104-03
PC2000-8 5
SEN02104-03 40 Troubleshooting
6 PC2000-8
40 Troubleshooting SEN02104-03
Cause
P1R or P2R P1F or P2F L1 or L2 R1 or R2
pump pump control valve control valve
PC2000-8 7
SEN02104-03 40 Troubleshooting
Suction valve
Safety valve
Servo valve
EPC valve
PPC valve
Main body
Main body
Jet sensor
Strainer
Spool
PTO
Failure mode
Whole work equipment
8 PC2000-8
Q
PPC cutoff valve
Q Q
Throttle shift valve
Q
Variable back pressure valve
PC2000-8
Travel junction valve
Q
Q
Q Q
Center swivel joint
Q
Variable back pressure valve
Q
Swing priority valve
40 Troubleshooting
Q
Q
Q
2-stage main relief valve
Arm throttle valve (L1)
Q 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
Bottom open (L1)
Q
Bottom open (L2)
Bottom close (L1)
Q
Q Q Q Q
Q Q Q Q
Bottom close (L2)
Solenoid (LS)
Q
Q
Q
Brake
Internal oil leakage
Q Q
Q Q Q
Q
Safety valve
Suction valve
Swing motor
Q Q Q
Q Q Q
Q Q Q
Q Q
Q Q
Q
Q Q
Q
Main body
Q
Brake
Internal oil leakage
Q
Safety valve
Travel motor
Q Q
Q
Q Q Q Q
Main body
Q
Q
Q
Swing machinery
Q
Q
Final gear
Q
Q
Q
Q
Q
Hydraulic cylinder
Q
Q
Engine system
Fan pump
Fan motor
Diagnostic code
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
9
SEN02104-03
H-11
Q 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-30
H-29
H-10
SEN02104-03 40 Troubleshooting
10 PC2000-8
40 Troubleshooting SEN02104-03
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.
PC2000-8 11
SEN02104-03 40 Troubleshooting
12 PC2000-8
40 Troubleshooting SEN02104-03
PC2000-8 13
SEN02104-03 40 Troubleshooting
14 PC2000-8
40 Troubleshooting SEN02104-03
PC2000-8 15
SEN02104-03 40 Troubleshooting
16 PC2000-8
40 Troubleshooting SEN02104-03
PC2000-8 17
SEN02104-03 40 Troubleshooting
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.
• Make sure that the other work equipment, travel and swing speed is normal. (If not, troubleshoot the
related items.)
Related
• Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot
information
the related items.)
• Set the working mode in P-mode when troubleshooting is carried out.
• Make sure that the electric circuit of heavy lift solenoid valve is normal before troubleshooting.
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.
• Make sure that the other work equipment, travel and swing speed is normal. (If not, troubleshoot the
related items.)
Related
• Make sure that the machine does not deviate during traveling. (If machine deviates, troubleshoot
information
the related items.)
• Set the working mode in P-mode when troubleshooting is carried out.
• Check the electric circuit of machine push-up solenoid valve first.
18 PC2000-8
40 Troubleshooting SEN02104-03
PC2000-8 19
SEN02104-03 40 Troubleshooting
20 PC2000-8
40 Troubleshooting SEN02104-03
PC2000-8 21
SEN02104-03 40 Troubleshooting
Trouble • Hydraulic drift of work equipment is large. (2) Hydraulic drift of arm is large
Related
information
Trouble • Hydraulic drift of work equipment is large. (3) Hydraulic drift of bucket is large
Related
information
22 PC2000-8
40 Troubleshooting SEN02104-03
Trouble • Time lag of work equipment is large (2) Time lag of arm operation is large
Related
information
Trouble • Time lag of work equipment is large (3) Time lag of bucket operation is large
Related
information
PC2000-8 23
SEN02104-03 40 Troubleshooting
24 PC2000-8
40 Troubleshooting SEN02104-03
PC2000-8 25
SEN02104-03 40 Troubleshooting
26 PC2000-8
40 Troubleshooting SEN02104-03
Fig. 2 Defective sealing position of center swivel joint and machine deviation directions
PC2000-8 27
SEN02104-03 40 Troubleshooting
Fig. 2 Defective sealing position of center swivel joint and machine deviation directions
28 PC2000-8
40 Troubleshooting SEN02104-03
• 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
• Set the working mode in P-mode when troubleshooting is carried out.
PC2000-8 29
SEN02104-03 40 Troubleshooting
30 PC2000-8
40 Troubleshooting SEN02104-03
PC2000-8 31
SEN02104-03 40 Troubleshooting
32 PC2000-8
40 Troubleshooting SEN02104-03
PC2000-8 33
SEN02104-03 40 Troubleshooting
34 PC2000-8
40 Troubleshooting SEN02104-03
PC2000-8 35
SEN02104-03 40 Troubleshooting
36 PC2000-8
40 Troubleshooting SEN02104-03
• Upper structure overruns remarkably when it (2) Upper structure overruns remarkably when
Trouble
stops swinging stopped from swinging in either direction only.
Related
information
PC2000-8 37
SEN02104-03 40 Troubleshooting
• 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.
38 PC2000-8
40 Troubleshooting SEN02104-03
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
PC2000-8 39
SEN02104-03 40 Troubleshooting
40 PC2000-8
40 Troubleshooting SEN02104-03
PC2000-8 41
SEN02104-03 40 Troubleshooting
42 PC2000-8
40 Troubleshooting SEN02104-03
PC2000-8 43
SEN02104-03
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
44
SEN02105-02
PC2000-8
40 Troubleshooting 1
Troubleshooting of mechanical system
(S-mode)
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) ..................................................................................................... 14
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 17
S-9 Oil becomes contaminated quickly ......................................................................................................... 18
S-10 Fuel consumption is excessive............................................................................................................. 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 20
S-12 Oil pressure drops ................................................................................................................................ 21
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 22
1
SEN02105-02 40 Troubleshooting
2
40 Troubleshooting SEN02105-02
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
SEN02105-02 40 Troubleshooting
4
40 Troubleshooting SEN02105-02
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
SEN02105-02 40 Troubleshooting
Defective injector
start until the crankshaft revolves 2 turns at maximum.
This phenomenon does not indicate a trouble, however.
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
6
40 Troubleshooting SEN02105-02
in H-mode
in E-mode
switch ON and carry out When terminal B and terminal C at safety relay outlet are con-
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
SEN02105-02 40 Troubleshooting
Defective injector
Confirm recent repair history
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
Replacement of filters not carried out according to Operation and Maintenance
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
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
*2: Failure code [CA271], [CB271] and failure code [CA272], [CB272] in E-mode
*3: Failure code [CA273], [CB273] and failure code [CA274], [CB274] in E-mode
8
40 Troubleshooting SEN02105-02
c) Exhaust smoke comes out but engine does not start Causes
Fuel does not flow out if air bleeding plug of fuel filter is
While engine is Q Q w w
cranked with starting removed
motor, If spill hose from injector is disconnected, little fuel spills Q Q w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] in E-mode
9
SEN02105-02 40 Troubleshooting
machine operation
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
Engine oil replenished more frequently w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Rust and water are found when fuel tank is drained w w
Fuel is leaking from fuel piping w
When priming pump is operated, it makes no reaction or it is heavy w Q Q
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low Q w
gas is Black w Q w w
When engine is cranked, abnormal sound is generated around cylinder head 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
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] in E-mode
10
40 Troubleshooting SEN02105-02
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] in E-mode
11
SEN02105-02 40 Troubleshooting
Correct
Correct
Correct
Clean
Remedy
Add
12
40 Troubleshooting SEN02105-02
13
SEN02105-02 40 Troubleshooting
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
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
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
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Remedy
14
40 Troubleshooting SEN02105-02
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
*2: Failure code [CA122] and failure code[CA123] in E-mode
*3: Failure code [CA263], [CB263] and failure code [CA265], [CB265]
15
SEN02105-02 40 Troubleshooting
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
Dust indicator is red (if indicator is installed) w
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
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low Q w
When engine is cranked, interference sound is emitted from around turbocharger w
Check items
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
*2: Failure code [CA144] and failure code[CA145] in E-mode
16
40 Troubleshooting SEN02105-02
Turbocharger 1
q Long-time operation of engine at low idle or high idle
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
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
17
SEN02105-02 40 Troubleshooting
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
Clean
—
Remedy
18
40 Troubleshooting SEN02105-02
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
change on some cylinders 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
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] in E-mode
*2: Failure code [CA144] and failure code[CA145] in E-mode
19
SEN02105-02 40 Troubleshooting
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
operation
Suddenly increased Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Q Q w
Check
Remedy
20
40 Troubleshooting SEN02105-02
Replace
Replace
Correct
Clean
Clean
Clean
Clean
—
Remedy
Add
21
SEN02105-02 40 Troubleshooting
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-
Degree of
machine operation
Operated for long period E E E E
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
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
22
40 Troubleshooting SEN02105-02
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
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
23
SEN02105-02 40 Troubleshooting
operation
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, interference sound is emitted from around turbocharger 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
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
24
40 Troubleshooting SEN02105-02
Replace
Remedy
25
SEN02105-02
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
26
SEN02133-06
PC2000-8
PC2000-8 1
SEN02133-06 50 Disassembly and assembly
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
developed for other models. Each Installation
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
: for the following.
79 T-
* *** ****
-
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
2 PC2000-8
50 Disassembly and assembly SEN02133-06
PC2000-8 3
SEN02133-06 50 Disassembly and assembly
Polyethylene
LT-4 790-129-9040 250 g q Use to seal plugs for blank holes
container
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instantaneous adhesive.
ThreeBond Polyethylene q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Use mainly to bond metals, rubbers, plastics, and
woods.
q Instantaneous adhesive.
Aron-alpha Polyethylene q Quick-curing type (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes)
q Use mainly to bond rubbers, plastics, and metals.
q Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc q Use for fitted portions subjected to high tempera-
648-50 container
ture.
q Use to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container q Use to seal taper plugs, elbows, and nipples for
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube
q Use to seal flange surfaces and threaded portions.
Liquid gasket
4 PC2000-8
50 Disassembly and assembly SEN02133-06
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
LG-10 q Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket
NEVER- — — Can q Use for the mounting bolt in the high temperature
SEEZ area of the exhaust manifold and the turbocharger,
etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold brication performance, general purpose type.
SYG0-400LI-A
district
(*)
SYG0-160CNLI
(*)
q Use for parts under heavy load.
Molybde- Caution:
num disul- SYG2-400M 400 g × 10 Bellows-type q Do not use this grease for rolling bearings like
fide grease SYG2-400M-A 400 g × 20 container swing circle bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg Can q Use this grease for work equipment pins only
(G2-M) when installing them, but do not use it after-
ward.
SYG2-400T-A
Grease
Hyper White
SYG0-400T-A q Seizure resistance, heat resistance and water re-
G2-T, Bellows-type
(*) 400 g sistance higher than molybdenum disulfide
G0-T (*) container
SYG2-16CNT grease.
*: For cold 16 kg Can
SYG0-16CNT q Not conspicuous on machine since color is white.
district
(*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT
Bellows-type q Since this grease is biodegradable in short period,
*: For use at (*) 400 g
container it has less impact on microorganisms, animals,
high temper- SYGA-16CNB
16 kg Can and plants.
ature and SYGA-16CNBT
under high (*)
load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond — 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
PC2000-8 5
SEN02133-06 50 Disassembly and assembly
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
q Feature: Urea (organic system) grease with heat
resistance and long life, can be packed into the
Grease
G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
20 ml
PRIMER tainer (Effective period: four months after date of
580 SUPER manufacture)
417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
20 ml (Effective period: four months after date of
22M-54-27230 20 ml
PRIMER tainer (Effective period: four months after date of
435-95 manufacture)
q Use as primer for black ceramic-coated
SUNSTAR
glass surface and for hard polycarbonate-
GLASS
22M-54-27240 150 ml Can coated surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
PRIMER tainer (Effective period: four months after date of
GP-402 manufacture)
SUNSTAR q Use "S" in high-temperature season and "W"
PENGUINE in low-temperature season as adhesive for
Polyethylene
SEAL580 417-926-3910 320 ml glass.
container
SUPER "S" (Effective period: four months after date of
Adhesive
or "W" manufacture)
Sika Japan, q Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
container
For adhered window glass
256HV manufacture)
SUNSTAR q Use as adhesive for glass.
Ecocart (Spe-
PENGUINE 22M-54-27210 320 ml (Effective period: six months after date of
cial container)
SUPER 560 manufacture)
SUNSTAR
q Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
Caulking material
2505
SEKISUI q Use to seal front window.
Polyethylene
SILICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE
q Use to seal glass-to-glass joint. Translucent
TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL
manufacture)
381
6 PC2000-8
50 Disassembly and assembly SEN02133-06
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented 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 Q
Removal, installation 795T-621-1441 Push tool t 1 Q
of engine front seal 4 01050-32280 • Bolt t 3 Press fitting of oil seal
A
01582-02218 • Nut t 3
01640-22232 • 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 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 1 790-101-5421 Grip t 1 Press fitting of oil seal
F
assembly 01010-51240 Bolt t 1
2 796T-626-1120 Push tool t 1 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 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
PC2000-8 7
SEN02133-06 50 Disassembly and assembly
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part name Nature of work, remarks
Installation of
hydraulic pump input S 796T-867-1810 Push tool t 1 Press fitting of oil seal
shaft oil seal
Hydraulic pump Removal, installation of
S1 796-770-1301 Oil stopper q 2
assembly hydraulic pump
790-101-2501 Push puller t 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
Disassembly, assem-
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
1 796T-416-1010 Push tool t 1 N Q
Disassembly, assem-
Disassembly, assembly of
bly of travel PPC T1 2 796T-416-1030 Push tool t 1 N Q
travel PPC valve
valve
3 796T-416-1020 Push tool t 1 N Q
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
Hydraulic cylinder
assembly U 07281-03209 Clamp t
(Backhoe spec.)
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
791-863-1110 Push tool t 1
5
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
8 PC2000-8
50 Disassembly and assembly SEN02133-06
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part name Nature of work, remarks
PC2000-8 9
SEN02133-06 50 Disassembly and assembly
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part name Nature of work, remarks
796T-870-1150 Sleeve t 1
796T-870-1170 Sleeve t 1
796-870-1180 Adapter t 1
796T-870-1190 Plate t 1
796-900-1230 Screw t 1
Arm assembly V 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
X
(stuck glass) 2 20Y-54-13180 Adapter t 2 Fixture of window glass
10 PC2000-8
50 Disassembly and assembly SEN02133-06
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
A4 Plate
A4 Push tool
PC2000-8 11
SEN02133-06 50 Disassembly and assembly
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
A5 Push tool
12 PC2000-8
50 Disassembly and assembly SEN02133-06
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
PC2000-8 13
SEN02133-06
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 01-17 (01)
14
SEN02134-04
PC2000-8
PC2000-8 1
SEN02134-04 50 Disassembly and assembly
Removal
k Lower the work equipment completely to
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 If you drain the coolant or you disconnect
the heater hose when the coolant tempera-
ture in the radiator is high, you may be
scalded. In this case, wait until the coolant
temperature lowers and then drain the cool- 5. Drain hydraulic oil.
ant or disconnect the heater hose. 6 Hydraulic tank: 1,300 l
1. Collect the air conditioner refrigerant (R134a) 6. Disconnect hoses (2) to (6).
from air conditioner circuit in advance. a Prepare a container and oil plug to catch
a Ask professional traders for collecting and oil leaks.
filling operation of refrigerant.
a Never release the refrigerant to the atmo-
sphere.
k If refrigerant gets in your eyes, you
may lose your sight. Accordingly, put
on protective goggles, gloves and
working suits with long sleeves while
you are collecting the refrigerant or fill-
ing the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified per-
son.
q Refrigerant quantity: 950 ± 50 g
2 PC2000-8
50 Disassembly and assembly SEN02134-04
PC2000-8 3
SEN02134-04 50 Disassembly and assembly
18. 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.
19. Disconnect 2 negative terminals (23) and 2 22. Disconnect fuel hose (29) from the bottom rear
positive terminals (24). of the power container.
20. Disconnect connectors (25) and (26) from the 23. Disconnect hose clamps (30).
rear of the battery.
4 PC2000-8
50 Disassembly and assembly SEN02134-04
PC2000-8 5
SEN02134-04 50 Disassembly and assembly
6 PC2000-8
50 Disassembly and assembly SEN02134-04
Removal
1. Remove power container assembly, referring
to "Removal and installation of power container
assembly."
PC2000-8 7
SEN02134-04 50 Disassembly and assembly
13. Disconnect connector S27B (150) from back- a In the case of low-grade fuel specification,
side of DSB (door switch - behind). disconnect connector (141) from priming
pump timer (PPT) between brackets (24)
and (25).
18. Disconnect brackets (24) and (25). 22. Remove clip and disconnect harness (153).
8 PC2000-8
50 Disassembly and assembly SEN02134-04
23. Disconnect connectors L08A (154) and S27A 30. Disconnect connector L13 (157) from the front
(155). of machine in the pump room.
PC2000-8 9
SEN02134-04 50 Disassembly and assembly
10 PC2000-8
50 Disassembly and assembly SEN02134-04
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
the following figure.)
PC2000-8 11
SEN02134-04 50 Disassembly and assembly
53. Disconnect 2 tube clamps (56). a 60. and 61. are low-grade fuel specification only
60. Disconnect fuel hoses (142) and (143).
12 PC2000-8
50 Disassembly and assembly SEN02134-04
PC2000-8 13
SEN02134-04 50 Disassembly and assembly
80. Disconnect fuel hose (86). 85. Disconnect connectors V12 (91) and V11 (93)
q Standard specification from inside the No.1 main pump.
82. Disconnect 2 hoses (88). 88. Disconnect connector P35 (163) from the fan
pump (middle lower).
83. Disconnect hose clamp (89).
14 PC2000-8
50 Disassembly and assembly SEN02134-04
89. Disconnect suction tube (95) from the No.1 96. Disconnect connectors V14 (110) and V13
main pump. (111) from the No. 2 main pump.
90. Disconnect 3 hoses (96), (97) and (98) from 97. Disconnect harnesses (112) and (113).
the fan pump (middle lower).
98. Disconnect 2 hoses (114).
PC2000-8 15
SEN02134-04 50 Disassembly and assembly
103.Disconnect connectors (120). VH19, VH16, 111. Disconnect 2 harnesses (131) from the starting
VH18 and VH17 from the left. motor.
104.Disconnect terminal (121). 112. Disconnect harness (132) from the starting
motor.
105. Remove clips and disconnect 2 harnesses (122).
16 PC2000-8
50 Disassembly and assembly SEN02134-04
[*2]
3 Air cleaner hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*3]
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)
2) Place the bridge (BR) under the clamping bolt
and adjust the overlapping (b) between the
116. Remove engine, PTO and pump assembly bridge (BR) and band to 5 mm minimum.
(136) mount bolts. [*9] (b) dimension: Min. 5 mm
Pump side mount bolts: (135) 3) Tightening of the clamp
Radiator side mount bolt: MB 2 Threaded portion (BC) of clamping bolt:
Lubricant (PANDO 18B from ThreeBond)
117. Lift and remove engine, PTO and pump a Never use an impact wrench.
assembly (136). q When the current hose is reused
4 Engine, PTO and pump assembly: Align the clamp position to the trace of the
6,100 kg clamp left on the hose.
3 Clamping bolt: Min. 6 Nm {0.6 kgm}
[*4]
3 Air tube clamp: 21 Nm {2.55 kgm}
[*5]
3 Radiator lower hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*6]
3 Radiator upper hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
PC2000-8 17
SEN02134-04 50 Disassembly and assembly
[*7]
q Adjust air conditioner compressor belt tension,
referring to "Testing and adjusting: Adjusting
air conditioner compressor belt tension."
[*8]
q Make sure inside (particularly the bottom) of
the controller connector is free from sands,
dusts or water. If such foreign substances are
present, clean them completely with the air
blow. (Sands, dusts or water can cause defect
contact or allow commingling of water.)
[*9]
a Note that the washer (U) in upper position is
different from the (D) in lower position on the
radiator side.
18 PC2000-8
50 Disassembly and assembly SEN02134-04
Removal
1. Remove clamp and drain coolant from the
hose (1).
6 Coolant: 180 l
[*1], [*2]
3 Radiator hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
PC2000-8 19
SEN02134-04 50 Disassembly and assembly
20 PC2000-8
50 Disassembly and assembly SEN02134-04
Installation
q Carry out the installation in the reverse order of
removal.
[*1]
3 Air tube clamp: 21 Nm {2.55 kgm}
[*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)
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
3) Tightening of the clamp
2 Threaded portion (BC) of clamping bolt:
Lubricant (PANDO 18B from ThreeBond)
a Never use an impact wrench.
PC2000-8 21
SEN02134-04 50 Disassembly and assembly
Removal
k Loosen the oil filler cap gradually to release
the internal pressure of the hydraulic tank
22 PC2000-8
50 Disassembly and assembly SEN02134-04
PC2000-8 23
SEN02134-04 50 Disassembly and assembly
Removal
1. Remove power container assembly, referring
to "Removal and installation of power container
assembly."
24 PC2000-8
50 Disassembly and assembly SEN02134-04
PC2000-8 25
SEN02134-04 50 Disassembly and assembly
26 PC2000-8
50 Disassembly and assembly SEN02134-04
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]
3 Radiator hose clamp:
34. Lift cooling (oil cooler, fuel cooler and fan) 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
assembly (42), 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 (oil cooler, fuel cooler and fan)
1) Align the hose to the original position (marked
assembly: 1,200 kg
position). (Air hose insertion depth: Min. 80 mm)
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
3) Tightening of the clamp
2 Threaded portion (BC) of clamping bolt:
Lubricant (PANDO 18B from ThreeBond)
a Never use an impact wrench.
[*3]
3 Air tube clamp: 21 Nm {2.55 kgm}
[*4]
3 Radiator hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
PC2000-8 27
SEN02134-04 50 Disassembly and assembly
Removal
1. Remove cooling assembly, referring to
"Removal and installation of cooling assem-
bly."
Installation
q Carry out the installation in the reverse order of
6. Remove fan bracket assembly (8) from the removal.
cooling assembly.
4 Fan bracket assembly: 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°)
28 PC2000-8
50 Disassembly and assembly SEN02134-04
Removal and installation of fuel 6. Disconnect fuel hoses (8) from the top rear of
tank assembly 1
the fuel tank.
PC2000-8 29
SEN02134-04 50 Disassembly and assembly
[*1]
3 Fuel tank mounting bolt:
1,520 – 1,910 Nm {155 – 195 kgm}
30 PC2000-8
50 Disassembly and assembly SEN02134-04
PC2000-8 31
SEN02134-04
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 05-10
32
SEN02135-07
PC2000-8
Engine
Engine............................................................................................................................................................. 2
Removal and installation of fuel supply pump assembly...................................................................... 2
Removal and installation of cylinder head assembly ........................................................................... 6
Removal and installation of fuel injector............................................................................................. 20
Removal and installation of engine front oil seal ................................................................................ 31
Removal and installation of engine rear oil seal................................................................................. 34
PC2000-8 1
SEN02135-07 50 Disassembly and assembly
Engine 1
Removal and installation of fuel 11. Disconnect fuel hose (13). [*4]
supply pump assembly 1
12. Remove lubrication tube (14).
Removal
k Lower the work equipment completely to 13. Remove bracket (15).
the ground and stop the engine. Standard specification
k
q
Lock the work equipment lock lever.
k Disconnect the cable from the negative (–)
terminal of the battery.
2 PC2000-8
50 Disassembly and assembly SEN02135-07
PC2000-8 3
SEN02135-07 50 Disassembly and assembly
2. Install supply pump assembly (16) in the fol- 4. Tighten the fuel supply pump assembly mount-
lowing procedure. ing bolts with the specified torque.
1) Insert supply pump by aligning unequal 5. Tighten bracket (15) and mounting bolts (17)
spline section (A) at the supply pump drive and (18) alternately.
case to the unequal spline section of sup- 3 Mounting bolt (17):
ply pump shaft. 59 – 74 Nm {6.0 – 7.5 kgm}
a If it is difficult to insert the supply 3 Mounting bolt (18):
pump into the port, slightly rotate the 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
crankshaft and change the position of 6. Install lubrication tube (14).
unequal spline section (A). 3 Lubrication tube joint bolts:
2) Tighten 3 mounting bolts (19) and mount- 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
ing bolt (19-1) with the fingers. 7. Install high-pressure pipe clamps (11) as fol-
a Use a reamer bolt and a spacer only lows.
at mounting bolt (19-1) to determine 1) Tighten both high-pressure pipe clamps
radial direction of the supply pump. (11) and bracket (9) by hand for temporary
installation.
2) Tighten clamps (11) permanently.
a Tighten the bolts carefully to prevent
excessive force to the high-pressure
tube.
3 Clamp bolts:
9.8 ± 1 Nm {1 ± 0.1 kgm}
3) Tighten bracket (9) permanently.
8. Install 4 rubber covers (10) onto sleeve nuts of
high-pressure pipe.
a Direct the slit section as follows during
installation.
q Fuel supply pump side: Downward
q Common rail system side: Inward (in
opposite direction)
4 PC2000-8
50 Disassembly and assembly SEN02135-07
[*4]
3 Joint bolts at filter (top) side of fuel hoses
(13): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Joint bolts at fuel supply pump side:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
a The fuel tube is used instead of fuel hoses (13)
in the right bank section.
q Bleeding air
Bleed air from the fuel system, referring to
“Bleeding air from fuel system” in Testing and
adjusting.
PC2000-8 5
SEN02135-07 50 Disassembly and assembly
New/Remodel
harnesses of the container assembly.
Sym-
Necessity
Part No. Part name q Engine hood (1)
4
bol
Sketch
Engine hood assembly: 210 kg
Q'ty
q Muffler and bracket assembly (2)
A 1 790-331-1110 Wrench q 1 q Disconnect hoses around the oil filter.
q Air hoses between air aftercooler and
Removal engine: Total 4 pieces
k Lower the work equipment completely to q Frame and air cleaner assembly (3)
4
the ground and stop the engine. Frame and air cleaner assembly: 270kg
k Lock the work equipment lock lever.
k Disconnect the cable from the negative (–) a Check whether all hose clamps and others
terminal of the battery. are disconnected.
6 PC2000-8
50 Disassembly and assembly SEN02135-07
3. Close the fuel valve through the bottom of fuel 10. Remove cover (9).
tank.
11. Disconnect fuel hoses (10).
4. Disconnect the right and left air cleaner hoses a Fuel hose (10-1) faces downward in the
(4). [*1] right bank section.
5. Remove cover (5). 12. Disconnect connectors (11), (12) and (13) from
sockets of engine controller (EC). [*2]
6. Disconnect connectors P41A, P41B, P41C
and P41D from the left, and then disconnect 13. Disconnect wiring harnesses (14).
wiring harness (6).
14. Remove engine controller, cooler and bracket
7. Remove plate (5-1) from the intake manifold. assembly (15).
a E: Ground cable
8. Disconnect wiring harnesses (7).
PC2000-8 7
SEN02135-07 50 Disassembly and assembly
8 PC2000-8
50 Disassembly and assembly SEN02135-07
29. Disconnect wiring harness (24). 38. Remove air intake connector (33). [*5]
a Remove the RH: electrical intake air
30. Remove fuel filter assembly (25). heater, too.
a Remove the harness clamp.
31. Remove oil tubes (26).
PC2000-8 9
SEN02135-07 50 Disassembly and assembly
10 PC2000-8
50 Disassembly and assembly SEN02135-07
55. Remove the following parts and components 59. Lift and remove turbocharger and exhaust
from the turbocharger (TC) unit. manifold assembly (57).
q Lubrication tube (52) 4 Turbocharger and exhaust manifold
q Lubrication drain tube (53) assembly: 60 kg
q Coolant tube (54) [*7]
q Coolant hose (55) [*7]
PC2000-8 11
SEN02135-07 50 Disassembly and assembly
12 PC2000-8
50 Disassembly and assembly SEN02135-07
PC2000-8 13
SEN02135-07 50 Disassembly and assembly
14 PC2000-8
50 Disassembly and assembly SEN02135-07
PC2000-8 15
SEN02135-07 50 Disassembly and assembly
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-DH)
k The clamp used for fixing a high-pressure 2) Tighten sleeve nut (82) on fuel injector
pipe must be a genuine Komatsu part and it (75) temporarily.
must be tightened to the specified torque. a If it is difficult to mount sleeve nut (82)
k Never bend a high-pressure pipe for the onto the threads of mount, push the
convenience sake. end of sleeve nut (82) toward the
k Before installing a high-pressure pipe, con- injector using the rod. Then rotate the
firm the following points. nut using a wrench.
If any abnormality was found, replace it 3) Temporarily tighten sleeve nut (84) at the
with another healthy one. Otherwise, leak- common rail section, too.
age of fuel can result. 4) Tighten and secure injector holder (80)
q Check that the taper seal portion of the permanently.
connection ((a) portion: areas 2 mm inside 3 Injector holder mounting bolt (74):
the tip) is free from visually recognizable 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
striations (b) or patchy dents (c). 5) Tighten the sleeve nut with the specified
q Check that nails are not caught by steps in torque.
portion (d) (2 mm inside the tip) (this por- a Use a commercially available (knuckle
tion is free from deformation). 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:
39.2 – 49 Nm {4 – 5 kgm}
a After having tightened the nuts, check
that O-rings (77) and (83) do not pro-
trude from sleeve nut (82).
16 PC2000-8
50 Disassembly and assembly SEN02135-07
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 pipes (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.
PC2000-8 17
SEN02135-07 50 Disassembly and assembly
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 pipes 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 brackets (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} [*3-1]
4) Tighten high-pressure pipe bracket (35) 3 Fuel tube (146) joint bolt and fuel tube (147)
permanently. upper side joint bolt:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3 Fuel tube (147) lower side joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*3-2]
3 Fuel tube (148) joint bolt and fuel tube (149)
upper side joint bolt:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3 Fuel tube (149) lower side joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*4]
3 Bracket assembly mounting bolts:
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}
18 PC2000-8
50 Disassembly and assembly SEN02135-07
Reference
Turbocharger assembly
2 Turbocharger assembly mounting bolts and
nuts:
Seizure prevention compound (LC-G)
(NEVER-SEEZ (Bostik, Inc.) or equivalent)
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}
PC2000-8 19
SEN02135-07 50 Disassembly and assembly
20 PC2000-8
50 Disassembly and assembly SEN02135-07
10. Disconnect connector L05B (10) from the bot- 14. Disconnect air cleaner hose (22). [*2]
tom of SWB.
PC2000-8 21
SEN02135-07 50 Disassembly and assembly
22 PC2000-8
50 Disassembly and assembly SEN02135-07
PC2000-8 23
SEN02135-07 50 Disassembly and assembly
24 PC2000-8
50 Disassembly and assembly SEN02135-07
55. Removal of rocker arm assembly 4) 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 screws (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.
PC2000-8 25
SEN02135-07 50 Disassembly and assembly
26 PC2000-8
50 Disassembly and assembly SEN02135-07
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)
screws (66) is securely placed in the k The clamp used for fixing a high-pressure
socket of pushrod. pipe must be a genuine Komatsu part and it
a When tightening the bolt, check that must be tightened to the specified torque.
adjustment screws (66) do not press the k Never bend a high-pressure pipe for the
pushrod. convenience sake.
2 Rocker arm shaft: k Before installing a high-pressure pipe, con-
Engine oil (EO30-DH) firm the following points.
2 Rocker arm assembly mounting bolt If any abnormality was found, replace it
threads and washer: with another healthy one. Otherwise, leak-
Engine oil (EO30-DH) age of fuel can result.
2 Rocker arm assembly mounting bolts: q Check that the taper seal portion of the
93 – 103 Nm {9.5 – 10.5 kgm} connection ((a) portion: areas 2 mm inside
a Adjust the valve clearance, and then the tip) is free from visually recognizable
tighten locknut (65). striations (b) or patchy dents (c).
a Adjust the valve clearance, referring to q Check that nails are not caught by steps in
"Checking and adjusting valve clearance" portion (d) (2 mm inside the tip) (this por-
of Testing and adjusting. tion is free from deformation).
3 Locknuts:
52.9 – 64.7 Nm {5.4 – 6.6 kgm}
a After having tightened the locknut, check
the valve clearance again.
PC2000-8 27
SEN02135-07 50 Disassembly and assembly
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-DH) 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 pipes (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):
58.8 – 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 clamps (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.
28 PC2000-8
50 Disassembly and assembly SEN02135-07
PC2000-8 29
SEN02135-07 50 Disassembly and assembly
q Bleeding air
Bleed air from the fuel system, referring to
“Bleeding air from fuel system” in Testing and
adjusting.
[*4]
3 Air tube clamp: 21 Nm {2.55 kgm}
30 PC2000-8
50 Disassembly and assembly SEN02135-07
Removal and installation of 7. Apply counter mark (E) on the damper and on
engine front oil 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 (7):
Q'ty
75 kg
Seal puller assem-
3 795-931-1100 t 1
bly 9. Remove engine front oil seal (8) in the follow-
795T-621-1430 Plate t 1 Q ing procedure.
A 795T-621-1441 Push tool t 1 Q
4 01050-32280 • Bolt t 3
01582-02218 • Nut t 3
01640-22232 • Washer t 3
Removal
k Lower the work equipment completely to
the ground and stop the engine.
k Lock the work equipment lock lever.
k Disconnect the cable from the negative (–)
terminal of the battery.
PC2000-8 31
SEN02135-07 50 Disassembly and assembly
Installation
1. Clean, degrease and then dry the contact sur-
face between the front cover and front seal.
32 PC2000-8
50 Disassembly and assembly SEN02135-07
[*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.
PC2000-8 33
SEN02135-07 50 Disassembly and assembly
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
Seal puller assem-
3 790-931-1110 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 engine rear oil seal (2).
a Take care in the removal not to damage
Removal the engine rear oil seal installation position
k Lower the work equipment completely to on the flywheel housing and the seal con-
the ground and stop the engine. tact face on the crankshaft.
k Loosen the hydraulic tank cap gradually to a Before removing, slightly drive the engine
release the inside pressure of the hydraulic rear oil seal in once to free it from fixation.
tank. a When engine rear oil seal (2) is fixed too
k Lock the work equipment lock lever. hard to the flywheel housing, carry out the
k Disconnect the cable from the negative (–) following procedure.
terminal of the battery. 1) Drill through a hole of approx. 3 mm
dia. on engine rear oil seal (2).
1. Drain the hydraulic oil. 2) Replace the tip of tool A3 with the drill
6 Hydraulic tank: 1,300 l type one.
3) Insert the top end of tool A3 into the
drilled hole, and remove the engine
2. Remove engine, PTO and hydraulic pump rear oil seal by the impact of slide
assembly referring to "Removal and installa- hammer (SH). (Apply the slide ham-
tion of engine, PTO and hydraulic pump mer evenly not to tilt the engine rear
assembly". oil seal.)
a Remove the metal powders completely.
3. Remove PTO assembly referring to "Removal a Take care not to damage crankshaft (4).
and installation of PTO assembly".
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
34 PC2000-8
50 Disassembly and assembly SEN02135-07
q Tool A3 Installation
PC2000-8 35
SEN02135-07 50 Disassembly and assembly
1. Installation procedure of standard seal 4) Apply rear seal (2) on the end of crank-
a Do not apply any grease, oil and others to shaft (4).
the seal lip surface (a). a Install the rear seal in the correct
a Never remove inside plastic cylinder (3) of dirention.
the standard spare seal before installing 5) Manually push the metal ring of rear seal
the seal.
(2) evenly, and insert in its position.
6) Using the tool A5, further press and insert
rear seal (2) evenly.
36 PC2000-8
50 Disassembly and assembly SEN02135-07
q Carry out the following installation in the 8) 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.
PC2000-8 37
SEN02135-07
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 08-17 (01)
38
SEN02136-02
PC2000-8
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
SEN02136-02 50 Disassembly and assembly
Power train 1
6. Disconnect hose (13). 10. Lift and remove output shaft (3).
Installation
q Carry out installation in the reverse order to
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
50 Disassembly and assembly SEN02136-02
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.
PC2000-8 3
SEN02136-02 50 Disassembly and assembly
6. Turn over PTO case assembly (7). 10. Using puller [4], remove gear and bearing
assembly (11) from the cage assembly (8).
4 PC2000-8
50 Disassembly and assembly SEN02136-02
PC2000-8 5
SEN02136-02 50 Disassembly and assembly
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.
6 PC2000-8
50 Disassembly and assembly SEN02136-02
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.
Front side
1. Remove 6 work equipment hoses (1).
Rear side
7. Disconnect connector BV1 (9) (mating part:
V19).
PC2000-8 7
SEN02136-02 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
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
50 Disassembly and assembly SEN02136-02
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
790-101-5621 Plate t 1
1 790-101-5421 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).
PC2000-8 9
SEN02136-02 50 Disassembly and assembly
10 PC2000-8
50 Disassembly and assembly SEN02136-02
11. Hub
1) Remove bolt (29).
2) Remove plate (30).
3) Remove hub (31).
5] Remove thrust washer (26).
PC2000-8 11
SEN02136-02 50 Disassembly and assembly
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).
13. Bearing
1) Remove bearing (36) from the case body
(33).
12 PC2000-8
50 Disassembly and assembly SEN02136-02
PC2000-8 13
SEN02136-02 50 Disassembly and assembly
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.
14 PC2000-8
50 Disassembly and assembly SEN02136-02
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
SEN02136-02 50 Disassembly and assembly
16 PC2000-8
50 Disassembly and assembly SEN02136-02
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:
Gasket sealant (LG-6)
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
PC2000-8 17
SEN02136-02 50 Disassembly and assembly
18 PC2000-8
50 Disassembly and assembly SEN02136-02
PC2000-8 19
SEN02136-02 50 Disassembly and assembly
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
k Lower the work equipment completely to
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.
20 PC2000-8
50 Disassembly and assembly SEN02136-02
Installation
q Carry out the installation in the reverse order of
removal.
[*1]
2 Mounting bolt: Liquid adhesive (LT-2)
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
SEN02136-02 50 Disassembly and assembly
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 eyebolts (M16 mm, P = 2.0), lift and
remove case assembly (1).
22 PC2000-8
50 Disassembly and assembly SEN02136-02
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).
PC2000-8 23
SEN02136-02 50 Disassembly and assembly
2] Using the press to push out shaft 2) Using eyebolts (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).
24 PC2000-8
50 Disassembly and assembly SEN02136-02
6. Shaft
Lift and remove shaft (38). 3) Lift and remove ring gear assembly (41).
PC2000-8 25
SEN02136-02 50 Disassembly and assembly
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).
26 PC2000-8
50 Disassembly and assembly SEN02136-02
PC2000-8 27
SEN02136-02 50 Disassembly and assembly
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.
28 PC2000-8
50 Disassembly and assembly SEN02136-02
PC2000-8 29
SEN02136-02 50 Disassembly and assembly
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.
30 PC2000-8
50 Disassembly and assembly SEN02136-02
PC2000-8 31
SEN02136-02 50 Disassembly and assembly
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).
Gasket sealant (LG-6)
a Thoroughly remove excessive
gasket that runs into the hole.
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
2 Mounting bolt: Adhesive (LT-2)
32 PC2000-8
50 Disassembly and assembly SEN02136-02
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 Mounting bolt: Adhesive (LT-2)
PC2000-8 33
SEN02136-02
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 01-17 (01)
34
SEN02137-03
PC2000-8
PC2000-8 1
SEN02137-03 50 Disassembly and assembly
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 PC2000-8
50 Disassembly and assembly SEN02137-03
Installation
q Carry out the installation in the reverse order of
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.
[*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
SEN02137-03 50 Disassembly and assembly
4 PC2000-8
50 Disassembly and assembly SEN02137-03
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
PC2000-8 5
SEN02137-03 50 Disassembly and assembly
6 PC2000-8
50 Disassembly and assembly SEN02137-03
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.
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).
PC2000-8 7
SEN02137-03 50 Disassembly and assembly
Installation
q Carry out the installation in the reverse order of
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
50 Disassembly and assembly SEN02137-03
PC2000-8 9
SEN02137-03 50 Disassembly and assembly
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: 350 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
k Lower the work equipment completely to
the ground and stop the engine.
k Loosen the cap of the hydraulic tank gradu-
ally to release the pressure inside the
hydraulic tank.
k Set the work equipment lock lever to the
lock position.
10 PC2000-8
50 Disassembly and assembly SEN02137-03
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).
PC2000-8 11
SEN02137-03 50 Disassembly and assembly
Assembly
1. Press bushings (9) to track roller (5).
12 PC2000-8
50 Disassembly and assembly SEN02137-03
Installation
q Carry out the installation in the reverse order of
removal.
[*1]
3 Roller mounting bolt:
1,520 – 1,910 Nm {155 – 195 kgm}
PC2000-8 13
SEN02137-03 50 Disassembly and assembly
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.
14 PC2000-8
50 Disassembly and assembly SEN02137-03
PC2000-8 15
SEN02137-03 50 Disassembly and assembly
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
50 Disassembly and assembly SEN02137-03
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.
PC2000-8 17
SEN02137-03 50 Disassembly and assembly
18 PC2000-8
50 Disassembly and assembly SEN02137-03
9. Disconnect hoses (6) to (14) from the center a Apply protective plates, to where the
swivel joint (SJ). slings on the back make contact.
a Fasten tags to hoses to identify them for
reinstallation.
PC2000-8 19
SEN02137-03 50 Disassembly and assembly
Installation
q Carry out the installation in the reverse order of
removal.
[*1], [*2]
2 Swing circle mating face:
Gasket sealant (LG-6)
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}
q Bleeding air
a Bleed air, referring to "Bleeding air from each
part" in Testing and adjusting.
20 PC2000-8
50 Disassembly and assembly SEN02137-03
Installation
2. Remove cover (4) from the top of counter- q Carry out the installation in the reverse order of
weight assembly (2). removal.
[*2]
a Install so that clearance to the power container
assembly shall be uniform to the left and right.
PC2000-8 21
SEN02137-03 50 Disassembly and assembly
Removal and installation of 8. Using a nylon sling etc., fix cylinder (6).
hydraulic ladder 1
a The nylon sling should be passed through
hole (a) of the frame for the ease of fixing.
Removal
1. Lower ladder (1) to the LOWER position.
6. Stop the engine. 10. Remove lock plate (10) of ladder pin (9) and
remove ladder pin (9).
7. Sling the end of ladder (1). a Perform the above operation for the 2
4 Ladder assembly: 170 kg places.
Installation
q Carry out installation in the reverse order to
removal.
22 PC2000-8
50 Disassembly and assembly SEN02137-03
PC2000-8 23
SEN02137-03
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 11-17 (01)
24
SEN02138-03
PC2000-8
Hydraulic system
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 (Backhoe specification) ................................... 31
Disassembly and assembly of hydraulic cylinder assembly (Loading shovel specification) ......................... 38
PC2000-8 1
SEN02138-03 50 Disassembly and assembly
Removal and installation of 4. Lift and remove hand rail (2) and floor (3).
hydraulic tank assembly 1
Removal
k Lower the work equipment completely to
the ground and stop the engine.
k Loosen the hydraulic tank cap gradually to
release the internal pressure.
k Lock the work equipment lock lever.
k Disconnect the cable from the negative (–)
terminal of the battery.
k If you drain the coolant or you disconnect
the heater hose when the coolant tempera-
ture in the radiator is high, you may be
scalded. In this case, wait until the coolant
temperature lowers and then drain the cool- 5. Disconnect clamps (4) and (5) and disconnect
ant or disconnect the heater hose. 4 air conditioner hoses (6) from the right side
of the hydraulic tank assembly.
1. Collect the air conditioner refrigerant (R134a)
from air conditioner circuit in advance. 6. Disconnect hoses (7) to (16).
a Ask professional traders for collecting and a Fasten tags to hoses to identify them for
filling operation of refrigerant. reinstallation.
a Never release the refrigerant to the atmo- a Clamp is provided to the hose (14).
sphere.
k If refrigerant gets in your eyes, you
7. Remove cover (17).
may lose your sight. Accordingly, put
on protective goggles, gloves and
working suits with long sleeves while
you are collecting the refrigerant or fill-
ing the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified per-
son.
q Refrigerant quantity: 950 ± 50 g
a Fasten tags to pipes and hoses to identify
them and show their installation position. This
helps prevent any mistakes when re-installing.
2 PC2000-8
50 Disassembly and assembly SEN02138-03
10. Disconnect suction tubes (22) and (23). 12. Disconnect connectors S23A (26) and S23B
(27) and disconnect harness (28).
PC2000-8 3
SEN02138-03 50 Disassembly and assembly
[*3]
2 Mounting bolt: Liquid adhesive (LT-2)
3 Hydraulic tank mounting bolt:
1,520 – 1,910 Nm {155 – 195 kgm}
4 PC2000-8
50 Disassembly and assembly SEN02138-03
PC2000-8 5
SEN02138-03 50 Disassembly and assembly
10. Disconnect air cleaner hose (11). [*1] 14. Remove cover (A) area.
6 PC2000-8
50 Disassembly and assembly SEN02138-03
PC2000-8 7
SEN02138-03 50 Disassembly and assembly
8 PC2000-8
50 Disassembly and assembly SEN02138-03
[*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}
PC2000-8 9
SEN02138-03 50 Disassembly and assembly
Necessity
a
Symbol
Sketch
Apply a thin coat of grease (G2-LI) on the out-
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.
10 PC2000-8
50 Disassembly and assembly SEN02138-03
Removal
k Lower the work equipment completely to
the ground and stop the engine.
k Loosen the cap of the hydraulic tank gradu-
ally to release the pressure inside the
hydraulic tank.
k Release remaining pressure in hydraulic
circuit, referring to "Releasing remaining
pressure in hydraulic circuit" in Testing and
adjusting.
k Set the work equipment lock lever to the
lock position.
k Disconnect the cable from the negative (–)
terminal of the battery.
Front overview
PC2000-8 11
SEN02138-03 50 Disassembly and assembly
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
50 Disassembly and assembly SEN02138-03
PC2000-8 13
SEN02138-03 50 Disassembly and assembly
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 (38): Without collar band
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
19. Remove 5 tubes (43).
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)
14 PC2000-8
50 Disassembly and assembly SEN02138-03
PC2000-8 15
SEN02138-03 50 Disassembly and assembly
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.
20. Remove mounting bolt and disconnect valve 27. Disconnect valve and bracket assembly (101).
(84).
28. Remove bracket (102).
16 PC2000-8
50 Disassembly and assembly SEN02138-03
q Bleeding air
Bleed air from the parts, refer to “Bleeding air
from various system” in Testing and adjusting.
PC2000-8 17
SEN02138-03 50 Disassembly and assembly
q L1 valve
1. Care should be taken for that spool, arm Lo
(AML), Boom Lo (BML) and bucket Hi (BH) are
directional.
18 PC2000-8
50 Disassembly and assembly SEN02138-03
q L2 valve
5. Core should be taken for that spool, arm Hi
(AMH), boom Hi (BMH) and bucket Lo (BL) are
directional.
PC2000-8 19
SEN02138-03 50 Disassembly and assembly
q R1 valve
7. Care should be taken for that spool, arm Lo
(AML), boom Hi (BMH) and bucket Lo (BL) are
directional.
20 PC2000-8
50 Disassembly and assembly SEN02138-03
q R2 valve
9. Care should be taken for that spool, Arm Hi
(AMH), boom Lo (BML) and bucket Hi (BH) are
directional.
PC2000-8 21
SEN02138-03 50 Disassembly and assembly
q Bleeding air
a Bleed air from the parts, refer to “Bleeding air
from various system” in Testing and adjusting.
22 PC2000-8
50 Disassembly and assembly SEN02138-03
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
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:
PC2000-8 23
SEN02138-03 50 Disassembly and assembly
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
q Carry out the installation in the reverse order of
removal.
[*1]
4 Swing motor assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
24 PC2000-8
50 Disassembly and assembly SEN02138-03
Removal
k Swing the work equipment by 90° and lower
it completely to the ground.
k Stop the engine.
k Release remaining pressure in hydraulic
circuit, referring to "Releasing remaining
pressure in hydraulic circuit" in Testing and
adjusting.
k Set the work equipment lock lever to the
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.
Installation
q Carry out the installation in the reverse order of
removal.
[*1]
3 Mounting bolt:
385 ± 42 Nm {39 ± 4 kgm}
q Bleeding air
Bleed air from the travel motor, referring to
"Bleeding air from each part" in Testing and
adjusting.
PC2000-8 25
SEN02138-03 50 Disassembly and assembly
Disassembly and assembly of In this section, only the precautions for disassem-
work equipment PPC valve bling and assembling the work equipment PPC
valve assembly are discribed.
assembly 1
Disassembly
a Spring (9) and spring (10) consists of each one
a In this section, only precautions for assembling of two types of springs with different installed
the work equipment PPC valve assembly are loads in four places, so check the mounting
explained. position (oil pressure port) and mark with tags
to prevent mistakes when installing.
Assembly
a When assembling, clean and inspect the parts
closely and take care fully so that dirt, rust,
flaw, etc. will not cause a trouble.
26 PC2000-8
50 Disassembly and assembly SEN02138-03
PC2000-8 27
SEN02138-03 50 Disassembly and assembly
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 796T-416-1010 Push tool t 1 N Q
T1 2 796T-416-1030 Push tool t 1 N Q
3 796T-416-1020 Push tool t 1 N Q
Disassembly
1. Remove screw (22) to damper assembly (21). 6. Remove seal (9) and collar (8).
2. Remove mounting bolt (19) to remove case 7. Remove piston (7) to remove retainer (6),
(18), shaft (16) and lever (13) assembly. springs (5) and (4) and shim (3).
a Store shim (3) after checking the thickness
3. Remove pin (17). and the number of shims at each mount-
ing position.
4. Remove shaft (16), bushings (14) (14a) and
lever (13) from the case. 8. Remove valve (2) from body (1).
28 PC2000-8
50 Disassembly and assembly SEN02138-03
Assembly
Only the precautions for assembling the travel PPC
valve assembly are discribed.
PC2000-8 29
SEN02138-03 50 Disassembly and assembly
30 PC2000-8
50 Disassembly and assembly SEN02138-03
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
796-720-1710 Ring (for arm) t 1
4 4) Disassemble piston rod assembly as fol-
07281-02709 Clamp t 1 lows.
796-720-1730 Ring (for boom) t 1] Set piston rod assembly (2) to tool
07281-03209 Clamp t U1.
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
01010-51240 Bolt t 1
2] Remove piston assembly stopper
screw (3).
Push tool kit
790-201-1500 t 1 Screw size:
(for bucket)
M12 × pitch 1.75: Arm, Bucket
790-201-1640 • Push tool 1 M16 × pitch 2 : Boom
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.
PC2000-8 31
SEN02138-03 50 Disassembly and assembly
32 PC2000-8
50 Disassembly and assembly SEN02138-03
PC2000-8 33
SEN02138-03 50 Disassembly and assembly
34 PC2000-8
50 Disassembly and assembly SEN02138-03
PC2000-8 35
SEN02138-03 50 Disassembly and assembly
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
(Loctite 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.
36 PC2000-8
50 Disassembly and assembly SEN02138-03
PC2000-8 37
SEN02138-03 50 Disassembly and assembly
Necessity
a Width across flats of hexagon socket
Symbol
Sketch
Q’ty
N/R
Part number Part name head bolt. Unit: mm
Cylinder
Cylinder repair Bottom
7 790-502-1003 t 1 Boom Arm Bucket
stand dump
8 790-720-1000 Expander t 1 Specification
796-720-1690 Ring t 1 Loading
27 19 21 19
07281-02169 Clamp t 1 shovel
9
796-720-1710 Ring t 1
2) Pull out piston rod assembly (3).
07281-02909 Clamp t 1
a Set an oil receiving pan under the cyl-
790-201-1701 Push tool kit t 1 inder to receive oil flowing out of the
790-201-1881 Push tool t 1 cylinder.
790-101-5021 Grip t 1
01010-50816 Bolt t 1
791-863-1110 Push tool t 1
10
790-101-5421 Grip t 1
U 01010-51240 Bolt t 1
792-725-1300 Push tool t 1
790-101-5421 Grip t 1
01010-51240 Bolt t 1
790-201-1500 Push tool kit t 1
790-201-1690 Plate t 1
790-101-5021 Grip t 1
01010-51240 Bolt t 1
792-715-1400 Plate t 1
11
790-101-5421 Grip t 1
01010-51240 Bolt t 1
792-725-1500 Plate t 1
790-101-5421 Grip t 1
01010-51240 Bolt t 1
38 PC2000-8
50 Disassembly and assembly SEN02138-03
2. Piston assembly and head assembly 7) Remove head assembly (2) from piston
1) Fix the head side of piston rod assembly rod (3).
(3) with tool U7 or a press.
2) Remove screws (7) to remove piston
assembly 1 (8).
3) Remove pin (4) and balls (5), then remove
plunger (6).
4) Remove O-ring and backup ring (9) from
plunger (6).
5) Remove piston assembly 2 (10).
PC2000-8 39
SEN02138-03 50 Disassembly and assembly
40 PC2000-8
50 Disassembly and assembly SEN02138-03
4) Fit wear rings (13). 3) Fit O-ring and backup ring (9) to plunger
5) Fit rings (12). (6).
a Take care not to increase the gap of a This work is not necessary for the
the piston ring too much. boom cylinder.
2 Ring groove: Grease (G2-LI) 4) Set plunger (6) to piston rod (3), then set
6) Fit O-ring and backup ring (11). balls (5) and install pin (4).
a This work is not necessary for the
boom cylinder.
a Check the number of the balls.
a After installing the pin, check that
there is play at the end of the plunger.
5) Install piston assembly 2 (10) and piston
assembly 1 (8), then secure them with
screws (7).
a Clean the threads of screws (7). After
tightening screws (7), caulk them.
PC2000-8 41
SEN02138-03 50 Disassembly and assembly
4. Cylinder assembly
1) Fix the bottom side of cylinder assembly
(1) with tool U7 or a press.
2) Install piston rod assembly (3).
2 Sealed part: Grease (G2-LI)
a Bring the gap of the ring in the hori-
zontal position (on the side of the pis-
ton rod), then insert the piston rod,
aligning it with the cylinder tube.
a After inserting the piston rod, check
t ha t th e r i ng i s n ot da ma ge d or
removed, then push in the piston rod
to the end.
Tightening torque
Boom 1,770.0 Nm {180.5 kgm}
Arm 510 Nm {52 kgm}
Bucket 890.0 Nm {90.8 kgm}
Bottom dump 510 Nm {52 kgm}
42 PC2000-8
50 Disassembly and assembly SEN02138-03
PC2000-8 43
SEN02138-03
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
44
SEN02139-01
PC2000-8
Work equipment
Work equipment .............................................................................................................................................. 2
Removal and installation of bucket cylinder assembly (Backhoe specification)................................... 2
Removal and installation of bucket cylinder assembly (Loading shovel specification)......................... 4
Removal and installation of bucket assembly (Backhoe specification) ................................................ 6
Removal and installation of bucket assembly (Loading shovel specification) ...................................... 8
Removal and installation of arm cylinder (Backhoe specification) ..................................................... 10
Removal and installation of arm cylinder (Loading shovel specification) ........................................... 12
Removal and installation of arm assembly (Backhoe specification) .................................................. 13
Removal and installation of arm assembly (Loading shovel specification) ........................................ 15
Removal and installation of boom cylinder assembly (Backhoe specification) .................................. 16
Removal and installation of boom cylinder assembly (Loading shovel specification) ........................ 18
Removal and installation of boom assembly (Backhoe specification)................................................ 20
Removal and installation of boom assembly (Loading shovel specification) ..................................... 22
Removal and installation of bottom dump cylinder assembly (Loading shovel specification) ............ 24
PC2000-8 1
SEN02139-01 50 Disassembly and assembly
Work equipment 1
2 PC2000-8
50 Disassembly and assembly SEN02139-01
Installation
q Carry out the installation in the reverse order of
removal.
[*1]
2 Internal bushing surface during pin assem-
bly: Anti-friction 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: Anti-friction 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
a For details, see Testing and adjusting, "Air
bleeding from each component."
PC2000-8 3
SEN02139-01 50 Disassembly and assembly
Removal and installation of 5. Lower bucket cylinder assembly onto stand [1].
bucket cylinder assembly
(Loading shovel specification) 1
Removal
k Extend the arm cylinder fully, set the bot-
tom of the bucket horizontal, lower the
work equipment completely to the ground
and stop the engine. Operate the control
levers several times to release the remain-
ing pressure in the hydraulic piping.
k Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
a Fit blind plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering.
6. Remove plate (4) and lock plate (5), then pull
1. Sling bucket cylinder assembly, and remove out bottom pin (6). [*2]
lock plate, then using forcing screws (Thread a Pull out the pin to a position where the cyl-
dia. = 24 mm, Pitch = 3.0 mm), remove rod pin inder bottom can be disconnected.
(1). [*1]
4 Pin: 68 kg
4 Pin: 51 kg
4 PC2000-8
50 Disassembly and assembly SEN02139-01
Installation
q Carry out installation in the reverse order to
removal.
[*1], [*2]
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 hole.
q Bleeding air
a For details, see Testing and adjusting, "Air
bleeding from each component."
PC2000-8 5
SEN02139-01 50 Disassembly and assembly
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.
6 PC2000-8
50 Disassembly and assembly SEN02139-01
Installation
q Carry out installation in the reverse order to
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]
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.
a Insert the O-ring at the end face of the bucket
boss securely.
PC2000-8 7
SEN02139-01 50 Disassembly and assembly
Removal and installation of 4. Sling bucket assembly, and remove plate (6)
bucket assembly (Loading shovel and lock plate (7), then pull out arm top pin (8).
[*2]
specification) 1
a Remove the pin on the other side in the
Removal same way.
k
4
Set the bottom of the bucket horizontal,
Pin: 105 kg
lower the work equipment completely to the
ground and stop the engine. Operate the
control levers several times to release the 5. Lift off bucket assembly (9).
4
remaining pressure in the hydraulic piping.
k
Bucket assembly: 14,315 kg
Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
a Fit blind plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering.
8 PC2000-8
50 Disassembly and assembly SEN02139-01
Installation
q Carry out installation in the reverse order to
removal.
[*1], [*2]
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 hole.
[*2]
q Insert one pin without being locked, after
inserting another pin, lock them.
q Bleeding air
a For details, see Testing and adjusting, "Air
bleeding from each component."
PC2000-8 9
SEN02139-01 50 Disassembly and assembly
Removal and installation of arm 5. Disconnect hose (4) and lubricating hose (5)
cylinder (Backhoe specification) 1
on the bottom 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.
10 PC2000-8
50 Disassembly and assembly SEN02139-01
[*2]
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.
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 11
SEN02139-01 50 Disassembly and assembly
Removal
k Retract boom cylinder fully, and extend arm
cylinder, then set the bottom of the bucket
horizontal, lower the work equipment com-
pletely to the ground and stop the engine.
Operate the control levers several times to
release the remaining pressure in the
hydraulic piping.
k Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
a Fit blind plugs in the hoses after disconnecting 5. Lift off arm cylinder assembly (4) carefully.
them, to prevent dirt or dust from entering.
4 Arm cylinder assembly: 1,100 kg
1. Sling arm cylinder assembly, and remove lock
plate, then using forcing screws (Thread dia. =
24 mm, Pitch = 3.0 mm), pull out pin (1). [*1]
a Pull out the pin to a position where the pis-
ton rod can be disconnected.
4 Pin: 28 kg
Installation
q Carry out installation in the reverse order to
removal.
[*1], [*2]
2 Inside surface of bushing when assembling
2. Start engine and retract piston rod fully.
k Tie the rod with wire to prevent it from
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin:
coming out.
Grease (LM-G)
k When aligning the position of the pin hole,
3. Disconnect hoses (2).
never insert your fingers in the hole.
4. Sling piston rod end and bottom end, and
remove lock plate, then using forcing screws q Bleeding air
(Thread dia. = 24 mm, Pitch = 3.0 mm), pull out a For details, see Testing and adjusting, "Air
pin (3). [*2] bleeding from each component."
a Pull out the pin to a position where the cyl-
inder bottom can be disconnected. q Refilling with oil (hydraulic tank)
a Add oil through oil filler to the specified
4 Pin: 28 kg level. Run the engine to circulate the oil
through the system. Then check the oil
level again.
12 PC2000-8
50 Disassembly and assembly SEN02139-01
Removal and installation of arm 3. Disconnect greasing hose (1) from inside.
assembly (Backhoe specification)1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
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
796-900-1230 Screw t 1
V
01582-33024 Nut t 1 4. Remove plate (2).
01643-33080 Washer t 1
5. Temporarily lift the arm cylinder and pull out
Puller pin (3) on the arm cylinder head side. [*1]
790-101-4000 t 1
(1,471 kN {150 ton}) a If the pin would not be pulled out, pull out
790-101-1102 Pump t 1 the pin on the head side using a bolt or
eyebolt.
Removal
1. Remove the bucket assembly, referring to 6. Start the engine and contract the piston rod.
"Removal of bucket assembly." Bind the piston rod with wire to prevent it from
falling out.
2. Fix the link to the arm using a wire.
k Extend the arm cylinder piston rod to 7. Set block [3] between the arm cylinder and the
approx. 200 mm before the end of exca- boom, and place the arm cylinder on block [3].
vating stroke. Lower the arm on to
block [1] and blocking tool [2]. 8. Disconnect 2 bucket cylinder hoses (4).
k Set the lock lever to the lock position
and stop engine. 9. Disconnect greasing tube (5).
PC2000-8 13
SEN02139-01 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
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]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
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
q Bleeding air
a For details, see Testing and adjusting, "Air
bleeding from each component."
14 PC2000-8
50 Disassembly and assembly SEN02139-01
Removal and installation of arm 6. Sling arm assembly, and remove lock plate,
assembly then using forcing screws (Thread dia. = 24
mm, Pitch = 3.0 mm), pull out boom top pin (8).
(Loading shovel specification) 1
[*1]
Removal a Pull out the pin on the other side in the
1. Remove bucket assembly. same way to a position where the arm can
For details, see Removal of bucket assembly. be disconnected from the boom.
4 Pin: 99 kg
2. Start engine, and set work equipment so that
bucket cylinder is perpendicular.
7. Lift off arm assembly (9).
4
3. Disconnect grease hose (1).
Arm assembly: 6,850 kg
4. Disconnect cylinder hoses (2).
a Disconnect 6 hoses between boom and
arm, and 6 hoses between arm and cylin-
der.
Installation
q Carry out installation in the reverse order to
removal.
5. Disconnect arm cylinder from arm.
For details, see Removal of arm cylinder [*1]
2
assembly. Inside surface of bushing when assembling
a Secure the arm cylinder assembly to the pin: Anti-friction compound (LM-P)
2 Grease after assembling pin:
boom with lever block [1].
Grease (LM-G)
a When aligning the position of the pin hole,
never insert your fingers in the hole.
q Bleeding air
a For details, see Testing and adjusting, "Air
bleeding from each component."
PC2000-8 15
SEN02139-01 50 Disassembly and assembly
Removal and installation of boom 5. Start the engine and contract the piston rod.
cylinder assembly (Backhoe Bind the piston rod with wire to prevent it from
falling out.
specification) 1
1. Disconnect greasing hose (1). 9. Pull out pin (7) on the bottom side using an
eyebolt. [*2]
2. Remove lock plate (2).
16 PC2000-8
50 Disassembly and assembly SEN02139-01
[*2]
2 Inside surface of bushing when assembling
pin (7): Anti-friction compound (LM-P)
2 Grease after assembling pin (7):
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the pin hole.
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).
PC2000-8 17
SEN02139-01 50 Disassembly and assembly
Removal and installation of boom 4. Sling boom cylinder assembly, and remove
cylinder assembly (Loading lock plate, then using forcing screws (Thread
dia. = 24 mm, Pitch = 3.0 mm), pull out foot pin
shovel specification) 1
(4). [*2]
4
Removal
k
Pin: 87 kg
Extend the arm and bucket fully, lower the
work equipment completely to the ground
and stop the engine. Operate the control
levers several times to release the remain-
ing pressure in the hydraulic piping.
k Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
a Fit blind plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering.
18 PC2000-8
50 Disassembly and assembly SEN02139-01
Installation
q Carry out installation in the reverse order to
removal.
[*1]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
a When aligning the position of the pin hole,
never insert your fingers in the hole.
[*2]
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 hole.
a Adjust with shims (7) so that the clearance a
between bracket (6) and the bottom end face
of boom cylinder (5) is less than 1 mm.
q Shim thickness: 1.0, 1.5 mm
q Bleeding air
a For details, see Testing and adjusting, "Air
bleeding from each component."
PC2000-8 19
SEN02139-01 50 Disassembly and assembly
Removal and installation 7. Remove lock plate (6) and then remove 2
of boom assembly boom foot pins (7) using the eyebolt. [*1]
(Backhoe specification) 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.
5. Disconnect bucket cylinder hose (3) and arm 8. Lift and remove boom assembly (5).
cylinder hose (4).
20 PC2000-8
50 Disassembly and assembly SEN02139-01
Installation
q Carry out installation in the reverse order to
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.
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
a For details, see Testing and adjusting, "Air
bleeding from each component."
PC2000-8 21
SEN02139-01 50 Disassembly and assembly
Removal and installation of boom 5. Disconnect bottom dump cylinder hoses (3),
assembly (Loading shovel bucket cylinder hoses (4), and arm cylinder
hoses (5).
specification) 1
a When the hoses are disconnected, oil may
Removal spurt out, so loosen the hose flanges
1. Remove arm assembly. slowly before disconnecting.
For details, see Removal of arm assembly.
22 PC2000-8
50 Disassembly and assembly SEN02139-01
Installation
q Carry out installation in the reverse order to
removal.
[*1], [*2]
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 hole.
[*2]
a Adjust with shims (15) so that the clearance (a)
between bracket (14) and the end face of the
foot of boom (13) is less than 1 mm.
q Shim thickness : 1.0, 1.5 mm
q Bleeding air
For details, see Testing and adjusting, "Air
bleeding from each component."
PC2000-8 23
SEN02139-01 50 Disassembly and assembly
Removal and installation of 5. Remove plate (6), then using forcing screws
bottom dump cylinder assembly (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out
bottom pin (7). [*2]
(Loading shovel specification) 1
4 Pin: 26 kg
Removal
k Set the bottom of the bucket horizontal,
and retract the rod to a position where the
rod connecting pin of the bottom dump cyl-
inder can be removed. Then fit a block
under the bucket, lower the work equip-
ment completely to the ground and stop the
engine.
a Fit blind plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering.
24 PC2000-8
50 Disassembly and assembly SEN02139-01
Installation
q Carry out installation in the reverse order to
removal.
[*1], [*2]
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 hole.
q Bleeding air
a For details, see Testing and adjusting, "Air
bleeding from each component."
PC2000-8 25
SEN02139-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 03-08 (01)
26
SEN02140-03
PC2000-8
PC2000-8 1
SEN02140-03 50 Disassembly and assembly
2. Drain coolant.
6 Coolant: 180 l
2 PC2000-8
50 Disassembly and assembly SEN02140-03
11. Disconnect antenna wire (11) from the distribu- 16. Disconnect PPC hoses (16) from the front of
tion board of the cab base. 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
14. Disconnect PPC hoses (14). From the right 17. Remove the covers (17).
Boom lower: Brown
Boom raise: Green
Bucket dump: Black
Bucket curl: White
PC2000-8 3
SEN02140-03 50 Disassembly and assembly
q Filling of refrigerant
Fill the air conditioner circuit with the refriger-
ant (air conditioner gas: R134a).
a Filling amount: 950 ± 50 g
(per unit of air conditioner compressor)
a Two air compressors are used.
[*4]
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
4 PC2000-8
50 Disassembly and assembly SEN02140-03
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
Lifter
1 793-498-1210 t 4
X (Suction cup)
2 20Y-54-13180 Adapter t 2
PC2000-8 5
SEN02140-03 50 Disassembly and assembly
6 PC2000-8
50 Disassembly and assembly SEN02140-03
3) Evenly apply paint primer to the surfaces 4) Evenly apply glass primer to the sticking
to stick both-sided adhesive tapes and the surfaces of window glass (9).
surfaces out of those surfaces on opera- 2 Glass primer:
tor's cab (8) which will be coated with the SUNSTAR GLASS PRIMER 435-40
adhesive. a Do not apply the primer more than 2
2 Paint primer: times. (If it is applied more than 2
SUNSTAR PAINT PRIMER 435-95 times, its performance will be low-
a Do not apply the primer more than 2 ered.)
times. (If it is applied more than 2
times, its performance will be low-
ered.)
PC2000-8 7
SEN02140-03 50 Disassembly and assembly
4. Stick both-sided adhesive tape (6) along 8.5 5. Position the new window glass.
mm off from the inside edge of the glass stick- 1) Check the clearance between the window
ing section. glass and the operator's cab on the right,
a Do not remove the release tape of the left, upper, and lower sides, and then
both-sided adhesive tape on the glass adjust it evenly.
sticking side before sticking the glass. 4 Right-hand side window glass:
a When sticking the both-sided adhesive 40 kg
tape, do not touch the cleaned surface as Front window glass: 65 kg
long as possible. 2) Stick tapes [6] between window glass (9)
a Take that the both-sided adhesive tape will and operator's cab (8) and draw position-
not float at each corner of the window frame. ing line (n).
3) Cut the tape between window glass (9)
and operator's cab (8) with a knife, and
then remove the window glass.
a Do not remove the tapes left on the
window glass and operator's cab
before installing the window glass.
(The figure shows the operator's cab of
PC200.)
8 PC2000-8
50 Disassembly and assembly SEN02140-03
PC2000-8 9
SEN02140-03 50 Disassembly and assembly
10 PC2000-8
50 Disassembly and assembly SEN02140-03
PC2000-8 11
SEN02140-03 50 Disassembly and assembly
Installation
12 PC2000-8
50 Disassembly and assembly SEN02140-03
Removal
PC2000-8 13
SEN02140-03 50 Disassembly and assembly
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
Installation
q Carry out the installation in the reverse order of
removal.
[*1], [*2]
3 Mounting bolts:
455 – 565 Nm {46.5 – 58 kgm}
14 PC2000-8
50 Disassembly and assembly SEN02140-03
Removal and installation of a If the fuel level in the tank is higher than
service center 1
the fuel filler (a) of the tank, the fuel will
flow out. Accordingly, drain the fuel in
Removal advance.
PC2000-8 15
SEN02140-03 50 Disassembly and assembly
16 PC2000-8
50 Disassembly and assembly SEN02140-03
PC2000-8 17
SEN02140-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 04-09 (01)
18
SEN02141-03
PC2000-8
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 VHMS controller assembly....................................................................... 9
Removal and installation of Orbcomm terminal assembly for VHMS................................................... 9
PC2000-8 1
SEN02141-03 50 Disassembly and assembly
Electrical system 1
Removal and installation of air 5. Remove covers (5), (6) and (7).
conditioner unit assembly 1
6. Remove ducts (8) and (9).
Removal
k Lower the work equipment completely to
the ground and stop the engine.
k Set the work equipment lock lever to the
lock position.
k Disconnect the cable from the negative (–)
terminal of the battery.
k If you drain the coolant or you disconnect
the heater hose when the coolant tempera-
ture in the radiator is high, you may be
scalded. In this case, wait until the coolant
temperature lowers and then drain the cool-
ant or disconnect the heater hose.
1. Collect the air conditioner refrigerant (R134a) 7. Disconnect connector M84B (10) from under.
from air conditioner circuit in advance.
a Ask professional traders for collecting and 8. Remove plate (11) and disconnect 2 air condi-
filling operation of refrigerant. tioner hoses (12) and (13). [*1]
a Never release the refrigerant to the atmo-
sphere.
k If refrigerant gets in your eyes, you
9. Disconnect 2 heater hoses (14).
may lose your sight. Accordingly, put 10. Disconnect drain hose (15).
on protective goggles, gloves and
working suits with long sleeves while 11. Disconnect connector A35 (16).
you are collecting the refrigerant or fill-
ing the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified per-
son.
q Refrigerant quantity: 950 ± 50 g
2. Drain coolant.
6 Coolant: 180 l
2 PC2000-8
50 Disassembly and assembly SEN02141-03
12. Remove duct (17) for the foot. 20. Remove ducts (30) and (31).
PC2000-8 3
SEN02141-03 50 Disassembly and assembly
23. Remove air conditioner unit (36). 28. Remove air conditioner unit (44).
a (44): Underside of air conditioner unit
Reference
24. Remove defroster duct (37) and rear duct (38). a D1 and D2 are equipped with the following
ducts:
25. 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.
4 PC2000-8
50 Disassembly and assembly SEN02141-03
[*1], [*2]
a When installing the hoses of the air conditioner
circuit, take care that dirt, dust, water, etc. will
not enter them.
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8 or ZEXEL ZXL100PT
(equivalent to PAG46) to O-ring (70)).
2 Apply engine oil (EO15W-40) to threaded
part and seat of mounting bolt.
3 M6 bolt (width across flats: 10) for the piping:
8 – 12 Nm {0.8 – 1.2 kgm}
3 Hose thread M16 × 1.5 (Width across flats
19): 12 – 15 Nm {1.2 – 1.5 kgm}
3 Hose thread M22 × 1.5 (Width across flats
24): 20 – 25 Nm {2.0 – 2.5 kgm}
3 Hose thread M24 × 1.5 (Width across flats
27): 30 – 35 Nm {3.0 – 3.5 kgm}
PC2000-8 5
SEN02141-03 50 Disassembly and assembly
Installation
q Carry out the installation in the reverse order of
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
50 Disassembly and assembly SEN02141-03
PC2000-8 7
SEN02141-03 50 Disassembly and assembly
Removal
k Lower the work equipment completely to
the ground and stop the engine.
k Set the work equipment lock lever to the
lock position.
k Disconnect the cable from the negative (–)
terminal of the battery.
Installation
q Carry out the installation in the reverse order of
removal.
8 PC2000-8
50 Disassembly and assembly SEN02141-03
Installation
q Carry out the installation in the reverse order of
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
SEN02141-03
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 09-10
10
SEN01629-02
PC2000-8
PC2000-8 1
SEN01629-02 90 Diagrams and drawings
2 PC2000-8
Hydraulic circuit diagram Hydraulic circuit diagram
PC2000-8 (Backhoe specification)
PC2000-8 (Backhoe specification) Serial No.: 20001 – 20197
Serial No.: 20001 – 20197
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN01629-02
PC2000-8 3
Hydraulic circuit diagram Hydraulic circuit diagram
PC2000-8 (Backhoe specification)
PC2000-8 (Backhoe specification) Serial No.: 20198 and up
Serial No.: 20198 and up
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN01629-02
PC2000-8 5
Hydraulic circuit diagram Hydraulic circuit diagram
PC2000-8 (Loading shovel specification)
PC2000-8 (Loading shovel specification) Serial No.: 20001 – 20197
Serial No.: 20001 – 20197
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN01629-02
PC2000-8 7
Hydraulic circuit diagram Hydraulic circuit diagram
PC2000-8 (Loading shovel specification)
PC2000-8 (Loading shovel specification) Serial No.: 20198 and up
Serial No.: 20198 and up
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN01629-02
PC2000-8 9
90 Diagrams and drawings SEN01629-02
PC2000-8 11
SEN01629-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
12
SEN01630-09
PC2000-8
PC2000-8 1
SEN01630-09 90 Diagrams and drawings
2 PC2000-8
Electrical circuit diagram (1/14)
Electrical circuit diagram (1/14) PC2000-8
SEN01630-09
PC2000-8 3
Electrical circuit diagram (2/14)
Electrical circuit diagram (2/14) PC2000-8
SEN01630-09
PC2000-8 5
Electrical circuit diagram (3/14)
Electrical circuit diagram (3/14) PC2000-8
SEN01630-09
PC2000-8 7
Electrical circuit diagram (4/14)
Electrical circuit diagram (4/14) PC2000-8
SEN01630-09
PC2000-8 9
Electrical circuit diagram (5/14)
Electrical circuit diagram (5/14) PC2000-8
SEN01630-09
PC2000-8 11
Electrical circuit diagram (6/14)
Electrical circuit diagram (6/14) PC2000-8
SEN01630-09
PC2000-8 13
Electrical circuit diagram (7/14)
Electrical circuit diagram (7/14) PC2000-8
SEN01630-09
PC2000-8 15
Electrical circuit diagram (8/14)
Electrical circuit diagram (8/14) PC2000-8
SEN01630-09
PC2000-8 17
Electrical circuit diagram (9/14)
Electrical circuit diagram (9/14) PC2000-8
SEN01630-09
PC2000-8 19
Electrical circuit diagram (10/14)
Electrical circuit diagram (10/14) PC2000-8
SEN01630-09
PC2000-8 21
Electrical circuit diagram (11/14)
Electrical circuit diagram (11/14) PC2000-8
SEN01630-09
PC2000-8 23
Electrical circuit diagram (12/14)
Electrical circuit diagram (12/14) PC2000-8
SEN01630-09
PC2000-8 25
Electrical circuit diagram (13/14)
Electrical circuit diagram (13/14) PC2000-8
SEN01630-09
PC2000-8 27
Electrical circuit diagram (14/14)
Electrical circuit diagram (14/14) PC2000-8
SEN01630-09
PC2000-8 29
Connector list and stereogram
PC2000-8
Connector list and stereogram 1
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 CV01 070 20 VHMS controller AN-4 NE 3 Engine position sensor AY-1 S06 SWP 6 Boom shockless control switch P-9
A01 DRC 70 Intermediate connector AB-9, AL-9 CV02A 070 18 VHMS controller AN-5 NEL 3 Intermediate connector (Left bank) (Male) AW-2 S07 SWP 6 Beacon switch P-9
A02 DRC 70 Intermediate connector AB-9, AL-9 CV02B 070 12 VHMS controller AN-6 NER 2 Intermediate connector (Right bank) (Female) AW-2 S10 090 3 Horn switch Q-7
A03 DRC 70 Intermediate connector AB-9, AM-9 CV03A 070 18 VHMS controller AN-5 NF1 X 4 Service connector Z-7 S11 090 3 Dump counter switch S-8
A04 DRC 70 Intermediate connector AO-2 CV04A 070 14 VHMS controller AN-6 OLLV DT 2 Engine oil level sensor AY-6 S13 SWP 6 Step light switch Q-9
A05 DRC 40 Intermediate connector AO-2 CV04B 070 10 VHMS controller AN-6 P01 DT 3 Boom RAISE PPC pressure sensor AI-9 S13A M 2 Service connector
A06 DRC 70 Intermediate connector A-1 D01 SWP 8 Diode AC-1 P02 DT 3 Bucket CURL PPC pressure sensor AI-9 S14 M 3 PPC hydraulic lock switch R-8
A07 DT 6 Emergency stop switch BF-7 D02 SWP 8 Diode AC-2 P03 DT 3 Bucket DUMP PPC pressure sensor AI-9 S15 SWP 6 Grease mode select switch P-9
A08 DT 6 Emergency stop switch J-9 D03 SWP 8 Diode AC-2 P04 DT 3 Arm OUT PPC pressure sensor AH-9 S16 SWP 6 Room lamp switch Q-8
A09 DRC 40 Intermediate connector L-1 D04 KES1 2 Diode AC-2 P05 DT 3 Arm IN PPC pressure sensor AH-9 S17 SWP 6 Sub lamp switch Q-8
A10 DT 12 Intermediate connector AE-8 D05 SWP 8 Diode AC-2 P06 DT 3 Left swing PPC pressure sensor AH-9 S19A DT 4 Additional emergency engine stop switch BV-3
A11 DT 12 Intermediate connector AD-9 D06 8 Working lamp diode P07 DT 3 Right swing PPC pressure sensor AG-8 S19B DT 4 Additional emergency engine stop switch BU-8
A12 DT 12 Intermediate connector AD-9 D11 SWP 8 Diode (Hydraulic actuated ladder spec.) AJ-1 P08 DT 3 Right swing PPC pressure sensor AG-8 S23A DT 3 Hydraulic tank strainer proximity switch H-1
A13 DT 12 Intermediate connector AE-8 D12 SWP 8 Diode (Hydraulic actuated ladder spec.) AJ-1 P09 X 2 Right travel (forward) PPC pressure switch AG-8 S23B DT 3 Hydraulic tank strainer proximity switch I-1
A14 DT 12 Intermediate connector AE-4, AN-2 D13 SWP 8 Diode (Hydraulic actuated ladder spec.) AJ-1 P10 X 2 Right travel (reverse) PPC pressure switch AF-8 S24 DT 3 Ladder limit lamp M-4
A15 DT 6 Intermediate connector AN-3 D14 DT 2 Diode (Loading shovel spec.) AN-5 P11 X 2 Left travel (forward) PPC pressure switch AF-8 S27A DT 2 Engine room lamp switch H-9
A17 DT 4 Intermediate connector AE-4, AN-2 DA1 DT 2 Blower diode AB-5 P12 X 2 Left travel (reverse) PPC pressure switch AF-7 S27B DT 2 Engine room lamp switch I-9
A19 DT 2 Service connector (+12 V) DA2 DT 2 Blower diode AB-4 P13 X 2 Service valve PPC pressure switch S28 DT 2 Pump room lamp switch BF-7
A20 DT 6 Intermediate connector M-9 DA3 DT 2 Condenser diode AA-5 P17 DT 2 Service connector S29 DT 2 Cab base lamp switch AN-8
A20A Air heater relay terminal A-2 DA4 DT 2 Condenser diode AB-4 P19 DT 2 PTO oil temperature sensor BE-2 S30 DT 6 Step light switch B-6
A20B Air heater relay terminal B-2 DA5 DT 2 Compressor diode AA-4 P20 M 3 Fuel control dial Q-7 S30A DT 6 Maintenance light switch B-5
A21 DT 2 Intermediate connector G-9 DA6 DT 2 Compressor diode AB-4 P21A DT 2 Fuel level sensor C-3 S30B MW9Z-C1 6 Steplight switch (Hydraulic actuated ladder spec.) M-2
A22 DTP 4 Intermediate connector AO-1 DW1 KES1 2 Wiper diode P-2 P21C DT 2 Fuel level (High) sensor C-6 S31 DT 2 Grease remain Hi level D-9
A23 DTP 4 Intermediate connector A-1 DW2 KES1 2 Wiper diode P21D DT 2 Fuel level (Middle) sensor C-4 S31A DT 3 To ladder upper proximity switch A (Hydraulic actuated ladder spec.) M-2
A24 DTHD 1 Intermediate connector AP-2 DW3 KES1 2 Washer diode P21E DT 2 Fuel level (Low) sensor C-3 S31B DT 3 To ladder upper proximity switch B (Hydraulic actuated ladder spec.) L-2
A24 DT 12 Intermediate connector E-1 E01 HD36 14 Intermediate connector (Female) (connected to 815) AW-3 P22 DT 2 Hydraulic oil temperature sensor J-1 S32 DT 3 Grease remain Lo level E-9
A25 DT 2 Intermediate connector AE-8 ENBP DT 3 Blow-by pressure sensor AX-5 P23A DT 2 Air cleaner clogging sensor BC-6 S33 DT-A 12 Intermediate connector (Hydraulic actuated ladder spec.) M-4
A27 DT 4 Intermediate connector AP-2 ENG (L) DRC 60 Engine controller (Left bank) BA-8 P23B DT 2 Air cleaner clogging sensor BC-6 S35 DT 3 Proximity switch (between boom to arm) (Loading shovel spec.) AL-9
A28 DT 4 Full alarm connector (Hydraulic actuated ladder spec.) AC-4 ENG (R) DRC 60 Engine controller (Right bank) AZ-1 P24 DT 2 Radiator coolant level sensor F-9 S36 DT 3 Proximity switch (service center) BU-5
A28A DT 6 Full alarm connector (Hydraulic actuated ladder spec.) AC-4 F01 20 Fuse box AE-2 P25 AMP 3 VL1 pressure sensor G-1 S38 DT 4 Service center lower switch BI-4
A29 DT 4 Intermediate connector (backup lamp) (if equipped) M-2 F02 6 Fuse box AE-2 P26 AMP 3 VL2 pressure sensor E-1 S39 DT 4 Service center upper switch BQ-1
A31 DT 8 Emergency stop prolix switch AC-3 G SUMITOMO 3 G sensor (Left bank) AY-5 P27 DT 4 J/S differential pressure sensor (VL1) AK-9 S51 SWP 6 Service center switch (if equipped) P-7
A32 DT 6 Swing brake emergency drive switch AC-3 G SUMITOMO 3 G sensor (Right bank) BB-2 P28 DT 4 J/S differential pressure sensor (VL2) AJ-9 S52 Terminal 4 Eng stop switch in cabin Q-8
A33 DT 12 Pump 1 emergency drive switch AC-4 GND P29 DT 2 Air temperature sensor AK-1 SR1 Terminal 1 Wiper relay terminal Z-1, AA-1
Terminal 1 GND (Engine controller) (Left bank) AZ-6
A34 DT 12 Pump 2 emergency drive switch AC-3 CM850.L P32 AMP 3 VR1 pressure sensor C-6 SR1 Terminal 1 Wiper relay terminal AA-3, AB-2
A35 DT 3 Bottom dump control valve L-1, AA-6 GND.R Terminal 1 GND (Engine controller) (Right bank) AY-1 P33 AMP 3 VR2 pressure sensor C-7 SR2 Terminal 1 Wiper relay terminal Z-2, AA-1
A36 DT 12 Intermediate connector (Loading shovel spec.) AC-3 H01 DT 8 Intermediate connector Z-4 P34 AMP 3 Fan pump pressure sensor (O/C) BH-4 SR2 Terminal 1 Wiper relay terminal AA-3, AB-2
A37 DT 6 Intermediate connector (Loading shovel spec.) AK-9 H02 DT 12 Intermediate connector X-2 P35 AMP 3 Fan pump pressure sensor (RAD) BF-2 SR3 Terminal 1 Wiper relay terminal Z-2, AA-1
A37A DT 3 Intermediate connector (Loading shovel spec.) AN-3 H03 DT 8 Intermediate connector Z-4 P36 DT 4 J/S differential pressure sensor (VR1) F-1 SR3 Terminal 1 Wiper relay terminal AA-3, AB-3
A37B DT 4 Intermediate connector (Loading shovel spec.) AN-4 H04 DT 8 Intermediate connector Y-3 P37 DT 4 J/S differential pressure sensor (VR2) D-1 SR4 Terminal 1 Wiper relay terminal Z-2, AB-1
A38A DT-A 12 Intermediate connector (Hydraulic actuated ladder spec.) AN-7 H05 DT 20 Intermediate connector AB-7 P38 DT 2 Hydraulic oil low temperature sensor I-1 SR4 Terminal 1 Wiper relay terminal AB-2, AB-3
A38B DT-B 12 Intermediate connector (Hydraulic actuated ladder spec.) AN-7 H06 DT 12 Intermediate connector AB-7 P39 DT 2 Hydraulic oil level sensor K-1 ST1 DT 2 Stator motor BA-8
A38C DT 6 Intermediate connector (Hydraulic actuated ladder spec.) M-3 H07 DT 3 Intermediate connector W-9 P40 DT 2 Hydraulic oil filter clogging sensor I-1 ST2 DT 2 Stator motor BA-8
A38D DT-A 12 Intermediate connector (Hydraulic actuated ladder spec.) M-4 H11 090 2 Starting switch P-7 P41A DT 3 Intermediate connector (Exhaust temperature sensor) BC-3, BC-4 SW1 Terminal 1 Emergency stop switch C1 terminal BH-9
A39 DT 4 For cutting connector (Hydraulic actuated ladder spec.) AN-4 H14 DT 8 Intermediate connector Y-3 P41B DT 3 Intermediate connector (Exhaust temperature sensor) BC-3, BC-4 SW2 Terminal 1 Emergency stop switch N01 terminal BG-9
A45 DT 3 Proximity switch (Fuel quick charge) (if equipped) BP-9 H15 DT 8 Intermediate connector X-3 P41C DT 3 Intermediate connector (Exhaust temperature sensor) BC-3 SW3 Terminal 1 Emergency stop switch NC1 terminal BH-8
A54 DT 4 Intermediate connector AM-9 J1939 DT 4 Intermediate connector AX-1 P41D DT 3 Intermediate connector (Exhaust temperature sensor) BC-3, BD-2 SW4 Terminal 1 Emergency stop switch C2 terminal BH-9
A55 DT 12 Intermediate connector AN-6 JC01 6 Branch block (Left bank) AZ-9 P45 DT 3 Wiper proximity switch AQ-7 T01 Terminal 1 Cab GND W-2
A56 DT-A 12 Intermediate connector AE-8, BI-3 JC01 8 Branch block (Right bank) AY-1 P48 DT 3 Grease pump discharge pressure sensor D-9 T01 Terminal 1 Battery (Left) GND A-2
A57 DT 6 Intermediate connector AE-9, BI-2 JC02 6 Branch block (Left bank) BA-9 PAMB AMP 3 Ambient pressure sensor AW-4 T02 Radio body GND W-9
A58 DT 6 Intermediate connector BR-7 JC02 6 Branch block (Right bank) AY-1 PCV1 SUMITOMO 2 Fuel pump #1 (Left bank) AZ-6 T02 Terminal 1 Battery (Left) GND A-2
A59 DT-B 12 Intermediate connector BR-8 JC03 9 Branch block (Left bank) BA-9 PCV1 SUMITOMO 2 Fuel pump #1 (Right bank) BB-2 T03 Terminal 1 Battery (Left) GND M-4
A60 DT 4 Intermediate connector P-7 K01 3 Resistor PCV2 SUMITOMO 2 Fuel pump #2 (Left bank) AX-6 T06 Terminal 1 Radio body GND V-9
A61A DT 6 Intermediate connector BU-4 K01A DT 3 Pump 1 emergency drive resistance PCV2 SUMITOMO 2 Fuel pump #2 (Right bank) BB-2 T10A Terminal 1 Cab base GND AI-1
A61B DT 6 Intermediate connector BL-9 K01A M 2 Pump 1 emergency drive resistance AN-4 PFUEL AMP 3 Common rail pressure sensor (Left bank) BA-7 T10B Terminal 1 Cab base GND AJ-1
A61C DT 6 Intermediate connector BK-8 K01B M 2 Pump 2 emergency drive resistance AN-4 PFUEL AMP 3 Common rail pressure sensor (Right bank) BA-1 T11 Terminal 1 Cab base GND AI-1
A62 DT-A 12 Grease refill controller BT-6 L.P 14 Intermediate connector (Male) AW-3 PIM SUMITOMO 3 Boost pressure sensor BA-9 T12 Terminal 1 Cab base GND AJ-1
A63 DT 2 Grease high level sensor BL-9 L.S 14 Intermediate connector (Female) AW-3 POIL FRAMATOME 4 Oil pressure sensor BA-7 T14 Terminal 1 Revolving frame GND M-3
A64 DT 4 Grease refill open/close valve BQ-8 L01A DT 2 Boom working lamp, upper right R.P 14 Intermediate connector (Male) AX-1 TAMB PACKARD 2 Air temperature sensor BA-9
ANR1 Terminal 1 Alternator R terminal BB-4 L01B DT 2 Boom working lamp, upper left R.S 14 Intermediate connector (Female) AX-1 TB01 Terminal 1 Cab base GND AP-1
ANR2 Terminal 1 Alternator R terminal BB-4 L01C DT 2 Boom working lamp, lower right R01A Terminal 1 Battery relay (Right) E terminal M-7 TB02 Terminal 1 Cab base GND AP-1
B01 DTHD 1 Intermediate connector AP-3 L01D DT 2 Boom working lamp, lower left R01B Terminal 1 Battery relay (Left) E terminal M-7 TB03 Terminal 1 Cab base GND AP-2
B02 DTHD 1 Intermediate connector AP-3 L02A DT 2 Fuel tank upper headlamp C-5 R02A Terminal 1 Battery relay (Right) BR terminal M-7 TB04 Terminal 1 Cab base GND AP-2
B03 DTHD 1 Intermediate connector AP-3 L02B DT 2 Fuel tank upper downlamp C-4 R02B Terminal 1 Battery relay (Left) BR terminal N-7 TB05 Terminal 1 Cab base GND AP-1
B04 DTHD 1 Intermediate connector AP-3 L03 M 2 Cab lamp AQ-8 R03A Terminal 1 Battery relay (Right) M terminal M-8 TB12 Terminal 1 GND AN-7
B05 DTHD 1 Intermediate connector AP-3 L04A DT 2 Headlamp AF-6 R03B Terminal 1 Battery relay (Left) M terminal M-7 TB13 Terminal 1 GND AC-8
B11 Terminal 1 Circuit breaker M-9 L04B DT 2 Headlamp AF-3 R03C Terminal 1 Battery relay (Right) M terminal M-8 TB14 Terminal 1 GND AC-8
B12A Terminal 1 Circuit breaker M-9 L04C DT 2 Headlamp AF-7 R03D Terminal 1 Battery relay (Left) M terminal M-7 TB15 Terminal 1 GND AD-9
B12B Terminal 1 Circuit breaker M-9 L04D DT 2 Headlamp AF-4 R04B Terminal 1 Battery relay (Left) B terminal M-8 TB16 Terminal 1 GND AD-9
B13 Terminal 1 Circuit breaker M-9 L05A DT 2 Beacon lamp AU-9 R05 5 PPC lock starter cut relay AC-4 TE01 Terminal 1 GND BE-2
B14A Terminal 1 Circuit breaker M-9 L05B DT 2 Intermediate connector J-9 R06 5 Hydraulic oil strainer off stating cut relay AC-4 TE02 Terminal 1 GND BH-6
B14B Terminal 1 Circuit breaker M-9 L05C DT 2 Beacon lamp (if equipped) J-9 R07 5 Step lamp relay AC-4 TE04 Terminal 1 GND BC-2
B15A Terminal 1 Circuit breaker N-9 L06 DT 2 Step lamp AV-8 R08 6 Work lamp relay AE-2 TE05 Terminal 1 GND BD-2
B15B Terminal 1 Circuit breaker M-9 L06B DT 2 Step and ladder lamps M-5 R09 6 Side rear lamp relay AE-3 TE06 Terminal 1 GND BD-2
B16A Terminal 1 Circuit breaker N-9 L07 DT 2 Flash lamp AF-2 R10 6 Right work lamp relay AE-3 TE07 Terminal 1 GND BE-2
B16B Terminal 1 Circuit breaker M-9 L08A DT 2 Engine room lamp G-9 R11 6 Left work lamp relay AE-3 TE08 Terminal 1 GND BE-2
B17 Terminal 1 Circuit breaker M-9 L08B DT 2 Engine room lamp L-8 R12 5 Swing holding brake relay AE-4 TFUEL PACKARD 2 Fuel temperature sensor (Left bank) AW-7
B18 Terminal 1 Circuit breaker M-8 L10 DT 2 Cab base lamp AN-8 R13 5 Flash light relay AE-4 TFUEL PACKARD 2 Fuel temperature sensor (Right bank) BB-3
B21A Terminal 1 Circuit breaker AO-8 L11 DT 2 Side lamp (Cab base) AN-5 R14 6 Horn relay AE-3 TIM PACKARD 2 Air intake manifold temperature sensor BA-9
B21B Terminal 1 Circuit breaker AO-8 L12 DT 2 Fuel tank upper-right downlamp C-5 R15A Terminal 1 Intake air heater relay N-8 TM1 Terminal 1 GND J-9
B21C Terminal 1 Circuit breaker AO-8 L13 DT 2 Pump room lamp BE-8 R15B Terminal 1 Intake air heater relay N-8 TOIL PACKARD 2 Engine oil temperature sensor BA-7
B22A Terminal 1 Circuit breaker AO-9 L14 DT 2 Left skew lamp (Cab base) AH-1 R15C Terminal 1 Intake air heater relay N-8 TR1 Terminal 1 GND (Revolving frame) K-1
B22B Terminal 1 Circuit breaker AO-9 L20 090 2 Emergency stop lamp O-7 R16A Terminal 1 Intake air heater relay N-9 TR2 Terminal 1 GND (Revolving frame) K-1
B22C Terminal 1 Circuit breaker AO-9 L21 090 2 Ladder warning lamp O-9 R16B Terminal 1 Intake air heater relay N-9 TR3 Terminal 1 GND (Revolving frame) K-1
B23A Terminal 1 Circuit breaker AO-9 L22 090 2 Automatic grease warning lamp O-9 R16C Terminal 1 Intake air heater relay N-8 TS1 Terminal 1 GND B-8, BG-8
B23B Terminal 1 Circuit breaker AO-9 L23 090 2 Fan reverse rotation warning lamp O-7 R17 5 Pre heater relay AD-5 TW1 Terminal 1 GND AR-8
B24A Terminal 1 Circuit breaker AO-9 L25 090 2 Strainer warning lamp O-8 R20 5 Beacon relay AC-4 TW2 Terminal 1 GND AR-1
B24B Terminal 1 Circuit breaker AO-9 L26 090 2 Emergency prolix warning lamp O-8 R30A 5 Blower relay AB-6 TWTR PACKARD 2 Coolant sensor BA-1
B25A Terminal 1 Circuit breaker AP-9 L27 DT 2 Indicator (Green) Q-8 R30B 5 Blower relay AB-6 V01 DT 2 Variable back pressure A-3
B25B Terminal 1 Circuit breaker AP-9 L28A DT 2 Indicator (Green) BV-3 R31A 4 Compressor relay AA-6 V02 DT 2 Swing priority A-3
B26A Terminal 1 Circuit breaker AO-8 L28B DT 2 Indicator (Green) BU-9 R31B 4 Compressor relay AB-6 V03 DT 2 Main 2-stage relief valve A-3
B26B Terminal 1 Circuit breaker AO-8 M01 PA 9 Radio V-9 R32A 5 Condenser relay AA-6 V04 DT 2 Arm throttle valve (Left) A-3
B27A Terminal 1 Circuit breaker AO-7 M02 M 2 Speaker (Left) AV-8 R32B 5 Condenser relay AA-5 V05 DT 2 Arm throttle valve (Right) A-4
B27B Terminal 1 Circuit breaker AO-7 M03 M 2 Speaker (Right) AT-9 R33A 5 Condenser relay (Hi) AA-6 V06 DT 2 Boom throttle valve A-4
B28A Terminal 1 Circuit breaker AP-7 M04 DT 2 Cigarette lighter U-9 R33B 5 Condenser relay (Hi) AA-5 V07 DT 2 Travel straight A-4
B28B Terminal 1 Circuit breaker AP-7 M05A DT 6 Upper wiper motor AS-8 R34 SHINAGAWA 6 Ladder lower stop relay (Hydraulic actuated ladder spec.) AN-9 V08 DT 2 2-stage safety valve boom head A-4
B28C Terminal 1 Circuit breaker AP-7 M05B DT 6 Lower wiper motor AR-1 R35 SHINAGAWA 6 Relay for fuel quick charge (Hydraulic actuated ladder spec.) AN-9 V09 DT 2 Boom shockless control valve AE-7
B29A Terminal 1 Circuit breaker AP-8 M06A KES 2 Window washer AM-1 R36 SHINAGAWA 6 Relay for PPC lock release (Hydraulic actuated ladder spec.) AN-9 V10 DT 2 Boom shockless control valve AD-7
B29B Terminal 1 Circuit breaker AP-8 M06B KES 2 Window washer AL-1 R37 SHINAGAWA 6 Relay for speed control (Hydraulic actuated ladder spec.) AN-9 V11 DT 2 No. 1 main pump EPC solenoid BH-5
B30A Terminal 1 Circuit breaker AP-8 M07A YAZAKI 2 Horn (Treble tone) AG-1 Upside proximity switch detection relay V12 DT 2 No. 1 main pump EPC solenoid BH-4
R38 SHINAGAWA 6 AN-8
B30B Terminal 1 Circuit breaker AP-8 M07B YAZAKI 2 Horn (Treble tone) AF-5 (Hydraulic actuated ladder spec.) V13 DT 2 No. 2 main pump EPC solenoid BH-5
C10 DT 3 Model selection pump controller Z-8 M08A YAZAKI 2 Horn (Bass tone) AF-2 R39 SHINAGAWA 6 Ladder down detection relay (Hydraulic actuated ladder spec.) AN-8 V14 DT 2 No. 2 main pump EPC solenoid BH-5
C11 DT 3 Model selection pump controller Z-6 M08B YAZAKI 2 Horn (Bass tone) AF-6 R40 SHINAGAWA 6 Upside proximity switch A trouble diagnosis relay AN-9 V15 DT 2 Fan pump BG-2
M10 DT 2 Service connector (+24 V) (Hydraulic actuated ladder spec.)
CE02 DRC 50 Engine controller (Left bank) BC-5 V16 DT 2 Fan pump BG-2
M11 M 4 DC/DC converter AD-1 R41 SHINAGAWA 6 Upside proximity switch B trouble diagnosis relay AN-9
CE03 DTP 4 Engine controller (Left bank) BC-5 (Hydraulic actuated ladder spec.) V17 DT 2 Fan pump reverse solenoid (O/C) BH-4
CE05 DRC 50 Engine controller (Right bank) BG-6 M12 DT 2 Service connector (+12 V) V-1 V18 DT 2 Fan pump reverse solenoid (RAD) H-9
R42 SHINAGAWA 6 Up solenoid control relay (Hydraulic actuated ladder spec.) AN-9
CE06 DTP 4 Engine controller (Right bank) BG-6 M14 DT 2 Travel alarm buzzer M-2 V19 DT 2 Bucket high cancel solenoid E-1
R43 SHINAGAWA 6 Lock release relay AD-5
CK01 DRC 40 ORBCOMM controller AN-3 M16 KES 2 Truck counter buzzer P-4 V20 DT 2 Swing parking brake G-1
R44 SHINAGAWA 6 Service center down detection relay AD-4
CM01 070 18 Monitor P-6 M27A YAZAKI 18 Air conditioner unit (Upper) Y-9 V21A DT 2 PPC hydraulic lock valve AD-7
R45 SHINAGAWA 6 Service center switch relay AD-5
CM02 070 12 Monitor P-5 M27B YAZAKI 18 Air conditioner unit (Lower) Y-9 V21B DT 2 PPC hydraulic lock valve AD-7
R46 SHINAGAWA 6 PPC lock release relay AD-5
CM05 IRA-A20 8 Rear camera (if equipped) M29A AMP 20 AC control panel T-9 V25 DT 2 Grease pump solenoid E-9
RES 2 Pull up resistor (Right bank) BA-1
CM850.L Terminal 1 GND (Engine controller) (Left bank) BA-8 M29B AMP 20 AC control panel T-9 V30 DT 2 OPT connector
RES1 2 Pull up resistor (Left bank) BA-8
CM850.R Terminal 1 GND (Engine controller) (Right bank) AZ-1 M30A AMP 16 AC control panel U-9 V31 DT 2 Ladder up solenoid (Hydraulic actuated ladder spec.) AF-6
RES2 3 Resistor (Left bank) AW-2
CN.ANR DT 2 Intermediate connector AX-1 M30B AMP 16 AC control panel T-9 V32 DT 2 Ladder down solenoid (Hydraulic actuated ladder spec.) AF-6
RES3 3 Resistor (Left bank) AW-2
CN1 2 Injector #1 (Left bank) AZ-5 M33A SUMITOMO 4 Air conditioner unit (Upper) Z-9 V33 DT 2 Speed control solenoid (Hydraulic actuated ladder spec.) AF-6
REV 2 Connector AW-3
CN1 2 Injector #1 (Right bank) BB-3 M33B SUMITOMO 4 Air conditioner unit (Lower) Y-9 V35 DT 2 Ladder down check solenoid valve (Hydraulic actuated ladder spec.) AF-6
RL1 SHINAGAWA 6 Bottom dump open L2 relay (Loading shovel spec.) AN-5
CN2 2 Injector #2 (Left bank) AZ-5 M34 X 1 A/C compressor electromagnetic clutch I-9 V35A DT 2 Arm dump close R1 (Loading shovel spec.) AC-4
RL2 SHINAGAWA 6 Bottom dump close L2 relay (Loading shovel spec.) AN-6
CN2 2 Injector #2 (Right bank) BB-3 M35 X 1 A/C compressor electromagnetic clutch H-9 V35B DT 2 Arm dump close L2 (Loading shovel spec.) AC-4
RL3 SHINAGAWA 6 Arm dump cushion relay (Loading shovel spec.) AN-4
CN3 2 Injector #3 (Left bank) AY-5 M36 DT 3 Condenser J-1 V36 DT 2 Service center upper solenoid BR-1
RL4 Terminal 1 Bottom dump priority relay (Loading shovel spec.) AN-4
CN3 2 Injector #3 (Right bank) BB-2 M36 DT 2 Air suspension seat R-8 V37 DT 2 Service center lower solenoid BP-8
RL6 Terminal 1 Bottom dump priority relay (Loading shovel spec.) AN-4
CN4 2 Injector #4 (Left bank) AY-5 M37 DT 3 Condenser J-1 V38 DT 2 Service center lower check valve BR-2
RL7 Terminal 1 Bottom dump priority relay (Loading shovel spec.) AN-4
CN4 2 Injector #4 (Right bank) BA-2 M79 M 2 Socket V-9 VH16 DT 2 Exhaust temperature sensor (LR) BD-7
RL8 Terminal 1 Bottom dump priority relay (Loading shovel spec.) AN-4
CN5 2 Injector #5 (Left bank) AX-5 M79A/M79B DT 4 Intermediate connector P-7 VH17 DT 2 Exhaust temperature sensor (RR) BD-8
RW1 4 Upper wiper relay Q-1
CN5 2 Injector #5 (Right bank) AY-5 M84A DT 4 Triple pressure switch Z-8 VH18 DT 2 Exhaust temperature sensor (RF) BD-8
RW2 4 Upper wiper brake relay P-1
CN6 2 Injector #6 (Left bank) AX-4 M84B DT 4 Triple pressure switch Z-6 VH19 DT 2 Exhaust temperature sensor (LF) BC-7
RW3 4 Lower wiper relay S-1
CN6 2 Injector #6 (Right bank) AX-4 N04 DT 12 Intermediate connector AC-2 VL1 DT 2 Bottom dump open L1 solenoid (Loading shovel spec.) M-5
RW4 4 Lower wiper brake relay S-1
CP01 DRC 24 Pump controller 1 Z-8 N05 DT 8 Intermediate connector AC-1 VL2 DT 2 Bottom dump open L2 solenoid (Loading shovel spec.) M-5
RW5 5 Washer relay T-1
CP02 DRC 40 Pump controller 1 Z-7 N06 DT 12 Service connector W-2 VL3 DT 2 Bottom dump close L1 solenoid (Loading shovel spec.) I-1
S01 6 Starter switch Y-2
CP03 DRC 40 Pump controller 1 Z-7 N07 DT 12 Multilink S-9 VL4 DT 2 Bottom dump close L2 solenoid (Loading shovel spec.) H-1
S02 SWP 6 Light switch Q-9
CP04 DRC 24 Pump controller 2 Z-5 N09A/B DT 3 Intermediate connector
S04 SWP 6 Swing lock switch Q-9
CP05 DRC 40 Pump controller 2 Z-5 NE 3 Intermediate connector (Left bank) (Female) AW-2
S05 SWP 6 Machine push up switch P-9
CP06 DRC 40 Pump controller 2 Z-5 NE 2 Intermediate connector (Right bank) (Male) AW-2
SEN01630-09
PC2000-8
31
90 Diagrams and drawings SEN01630-09
PC2000-8 33
SEN01630-09
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 08-17 (01)
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