PC600 (LC) 8 UEN00128 01 Troubleshooting

UEN00447-00
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
Machine model Serial number
PC600-8 K50001 and up

PC600LC-8 K50001 and up
40 Troubleshooting
General information on troubleshooting
General information on troubleshooting ............................................................................................................... 2

Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and procedures of troubleshooting ........................................................................................... 5
Connection table for connector pin numbers .................................................................................................. 9
T-boxes and T-adapters table ....................................................................................................................... 32
PC600-8 1
UEN00447-00 40 Troubleshooting
General information on troubleshooting

Points to remember when troubleshooting
k Stop the machine in a level ground, and check that the lock pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of
possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or a When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the a The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
6) When were these repairs carried out? • Even if the failure is repaired, if the root
7) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
2 PC600-8
40 Troubleshooting UEN00447-00
Sequence of events in troubleshooting
PC600-8 3
Checks before troubleshooting

Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil,
4. Check hydraulic oil strainer — Clean, drain

coolant
5. Check swing machinery oil level — Add oil

6. Check engine oil level (oil pan oil level) — Add oil
7. Check coolant level — Add coolant
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
equipment
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
mechanical
equipment
Hydraulic,
1. Check for abnormal noise, smell — Repair

2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30V Replace

2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment
3. Check for discolored, burnt, exposed wiring — Replace

4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention to — Disconnect
water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After Replace
running for
several
minutes :
27.5 – 29.5V
8. Check operating sound of battery relay — Replace
(when switch is turned ON/OFF)
4 PC600-8
Classification and procedures of troubleshooting

Classification of troubleshooting
Mode Contents
Display of code Troubleshooting when failure code (electrical system)/(mechanical system) is displayed
E-mode Troubleshooting for electrical system
H-mode Troubleshooting for hydraulic and mechanical system
S-mode Troubleshooting for engine unit
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to
the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, press the [ ] switch of the panel switch section in
the current condition to display the failure code.
Carry out troubleshooting in [Display of code] according to the displayed failure code of electrical system.
2. Procedure for troubleshooting to be taken when electrical system failure code or mechanical system
failure code is recorded in abnormality record:
If an action code is not displayed on the machine monitor, check for an electrical system failure code or
mechanical system failure code with the abnormality record function of the machine monitor.
If a code is recorded, carry out troubleshooting in [Display of code] according to that code.
a If failure codes of electrical system are recorded, delete all of them and reproduce them, and then see if
the trouble is still detected.
a A mechanical system failure code cannot be deleted.
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is not
recorded:
If an action code is not displayed and a abnormality record is not recorded in the machine monitor, a trouble
that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and
mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the
table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting
related to that phenomenon in the "E mode" or "H mode".
PC600-8 5
Failure-looking Phenomenon and Troubleshooting No.
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Action to be taken concerning User Code, Error Code and Failure Code
1 Display User Code in monitor panel Accord-
ing to
Display Failure Code in mechanical system after checking Abnormality displayed
2
Record code
Engine related failure
3 Starting performance is poor (starting always takes time) S-1
4 Engine does not turn E-1 S-2 a)
Engine turns but no exhaust smoke
5 S-2 b)
Engine does not start comes out
Exhaust smoke comes out but engine
6 S-2 c)
does not start (Fuel is being injected)
7 Engine does not pick up smoothly (follow-up is poor) S-3
8 Engine stops during operations S-4
9 Engine does not rotate smoothly (hunting) S-5
10 Engine lacks output (or lacks power) S-6
11 Exhaust smoke is black (incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Oil becomes contaminated quickly S-9
14 Fuel consumption is excessive S-10
15 Oil is in cooling water (or water spurts back, or water level goes down) S-11
16 Oil pressure caution lamp lights up (drop in oil pressure) S-12
17 Oil level rises (water, fuel in oil) S-13
18 Water temperature becomes too high (overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
21 Preheater does not operate E-2
22 Auto engine warm-up device does not work E-3
23 Auto-decelerator does not operate E-4
Failure related to work equipment, swing and travel
24 Speed or power of all work equipment, travel, and swing is low H-1
25 Engine speed lowers remarkably or engine stalls H-2
26 All work equipment, travel, and swing systems do not work E-5 H-3
27 Abnormal sound is heard from around pump H-4
Work equipment-related failure
28 Boom speed or power is low H-6
29 Arm speed or power is low H-7
30 Bucket speed or power is low H-8
31 Boom does not move H-9
6 PC600-8
Troubleshooting
display
32 Arm does not move H-10
33 Bucket does not move H-11
34 Hydraulic drift of work equipment is large H-12
35 Time lag of work equipment is large H-13
36 Power max. function does not operate E-6 H-14
37 Machine push-up function does not operate or stop E-7 H-16
When arm and boom • bucket are operated simultaneously,
38 H-17
boom • bucket speeds are low
When bucket and boom • arm • swing • travel are operated simulta-
39 H-19
neously, boom • arm • swing • travel speeds are low
40 When arm and swing are operated simultaneously, swing speed is low H-20
Travel related failure
41 Machine deviates in one direction H-20
42 Machine deviates largely at start H-21
43 Machine deviates largely during compound operation H-22
44 Travel speed or power is low H-23
45 Machine does not travel (only one track) H-24
46 Travel speed does not change H-25
47 Travel alarm does not sound or does not stop sounding E-29
Swing related falure
48 Upper structure does not swing H-26
49 Swing speed or acceleration is low H-27
50 Upper structure overruns excessively when it stops swinging H-28
51 Large shock is made when upper structure stops swinging H-29
52 Large abnormal sound is made when upper structure stops swinging H-30
53 Hydraulic drift of swing is large H-31
Machine monitor related failure (Operator’s Menu: Ordinary Display)
54 Any item is not displayed on machine monitor E-8
55 Part of display on machine monitor is missing E-9
56 Machine monitor displays contents irrelevant to the model E-10
57 Fuel level monitor red lamp lights up while engine is running E-11
58 Engine water thermometer does not display normally E-12
59 Hydraulic oil temperature gauge does not display correctly E-13
60 Fuel gauge does not display correctly E-14
61 Swing lock monitor does not display correctly E-15
62 When monitor switch is operated, nothing is displayed E-16
63 Windshield wiper and window washer do not work E-17
Machine monitor related failure (Service Menu: Special Function Display)
64 "Boom RAISE" is not correctly displayed in monitoring function E-18
PC600-8 7
Troubleshooting
display
65 "Boom LOWER" is not correctly displayed in monitoring function E-19
66 "Arm IN" is not correctly displayed in monitoring function E-20
67 "Arm OUT" is not correctly displayed in monitoring function E-21
68 "Bucket CURL" is not correctly displayed in monitoring function E-22
69 "Bucket DUMP" is not correctly displayed in monitoring function E-23
70 "Swing" is not correctly displayed in monitoring function E-24
71 "Travel" is not correctly displayed in monitoring function E-25
Other failure
72 Air conditioner does not work E-26
73 Step light does not light up or go off E-27
74 Electric grease gun does not operate E-28
8 PC600-8
Connection table for connector pin numbers

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
PC600-8 9
X type connector
No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
10 PC600-8
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
PC600-8 11
No.of M type connector

pins Male (female housing) Female (male housing) T-adapter Part No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
12 PC600-8
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
PC600-8 13
S type connector
No.of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
14 PC600-8
No.of MIC type connector

7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
PC600-8 15
No.of MIC type connector

17 799-601-2730
21 799-601-2740
—
(Q’ty: 50) (Q’ty: 50)
16 PC600-8
No.of AMP040 type connector

8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
a Terminal part No.: 79A-222-3470 (No relation with number of pins)
PC600-8 17
No.of AMP070 type connector

10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
18 PC600-8
No.of L type connector

2 —
— —
No.of Connector for PA

9 —
— —
No.of Bendix MS connector

10 799-601-3460
— —
PC600-8 19
No.of KES 1 (Automobile) connector

2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
20 PC600-8
No.of KES 1 (Automobile) connector

8 —
08027-10820 (Black) 08027-10870 (Black)
No.of Connector for relay (Socket type)

5 799-601-7360
— —
6 799-601-7370
— —
PC600-8 21
No.of F type connector

4 —
— —
22 PC600-8
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector
(shell
size Body (plug) Body (receptacle) T-adapter Part No.
code)
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
PC600-8 23
(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
24 PC600-8
(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
PC600-8 25
(shell
code)
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
26 PC600-8
(shell
code)
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
PC600-8 27
No.of DT Series connector
pins Body (plug) Body (receptacle) T-adapter Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
28 PC600-8
No.of DT Series connector
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
12GR:799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR:799-601-9140
PC600-8 29
No.of DTM Series connector
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
No.of DTHD Series connector
2 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
30 PC600-8
No.of DRC26 Series connector
24 799-601-9360
— Part No.:7821-93-3110
40
799-601-9350
(A)
— Part No.:7821-93-3120
40
799-601-9350
(B)
— Part No.:7821-93-3130
PC600-8 31
T-boxes and T-adapters table

a The Nos. in the columns are the part Nos. of the T-boxes, T-adapters, and other parts. The Nos. in the lines
are the kit Nos. of the T-adapter kits.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Out of kit
Identifica-
Part No. Part name
tion symbol
799-601-2600 T-box (for ECONO) 21 q q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3300 T-box (for ECONO) 24 q
799-601-3360 • Plate for MS (24-pin) q
799-601-3370 • Plate for MS (17-pin) q
799-601-3380 • Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4210 Adapter for DRC 50 DRC50 q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
32 PC600-8
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Out of kit
Identifica-
Part No. Part name
tion symbol
799-601-7320 Adapter for SWP 16 SW16P q

799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
PC600-8 33
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Out of kit
Identifica-
Part No. Part name
tion symbol

799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for DT/HD) 12 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410 Adapter for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 3 A3 q
799-601-9430 2 P q
799-601-9440 Adapter for engine (CRI-T2) 3 1,2,3 q
795-799-5520 Adapter for engine (HPI-T2) 2 S q
Adapter for engine (HPI-T2)
795-799-5530 2 C q
Adapter for engine (HPI-T2)
795-799-5540 2 A q
795-799-5460 Adapter for engine (HPI-T2) 3 q
799-601-4160 Adapter for engine (CRI-T3) 2 OIL q
799-601-4130 Adapter for engine (CRI-T3) 3 FCIN q
799-601-4140 Adapter for engine (CRI-T3) 3 FCIG q
799-601-4150 Adapter for engine (CRI-T3) 3 FCIB q
799-601-4180 Adapter for engine (CRI-T3) 3 FCIP3 q
799-601-4230 Adapter for engine (CRI-T3) 4 1,2,3,4 q
799-601-4260 Adapter for controller (ENG) 4 DTP4 q
799-601-4210 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4280 Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9370 Adapter for controller (HST) 26 HST26A q
34 PC600-8
PC600-8 35
PC600, 600LC-8 Hydraulic excavator
Form No. UEN00447-00
©2006 KOMATSU
All Rights Reserved
Printed in Belgium 02-06 (01)
36
UEN00448-00
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 K50001 and up

40 Troubleshooting
Troubleshooting by failure code
(Display of code), Part 1
Troubleshooting by failure code (Display of code), Part 1 ................................................................................... 4

Failure code table ........................................................................................................................................... 4
Before carrying out troubleshooting of displayed failure code ........................................................................ 8
Information contained in troubleshooting table ............................................................................................. 10
Failure code [A000N1] Eng. Hi Out of Std .................................................................................................... 13
Failure code [AA10NX] Aircleaner clogging ................................................................................................. 14
Failure code [AB00KE] Charge Voltage Low ................................................................................................ 16
Failure code [B@BAZG] Eng. Oil Press. Low .............................................................................................. 18
Failure code [B@BAZK] Eng. Oil Level Low ................................................................................................ 20
Failure code [B@BCNS] Eng. Water Overheat ............................................................................................ 21
Failure code [B@BCZK] Eng. Water Lvl Low ............................................................................................... 22
Failure code [B@HANS] Hydr. Oil Overheat ................................................................................................ 24
Failure code [CA111] ECM Critical Internal Failure ...................................................................................... 25
Failure code [CA115] Eng Ne and Bkup Speed Sens Error.......................................................................... 26
Failure code [CA122] Chg Air Press Sensor High Error ............................................................................... 28
Failure code [CA123] Chg Air Press Sensor Low Error................................................................................ 30
Failure code [CA131] Throttle Sensor High Error ......................................................................................... 32
Failure code [CA132] Throttle Sensor Low Error.......................................................................................... 34
Failure code [CA135] Eng Oil Press Sensor High Error ............................................................................... 36
Failure code [CA141] Eng Oil Press Sensor Low Error ................................................................................ 38
PC600-8 1
Failure code [CA144] Coolant Temp Sens High Error .................................................................................. 40

Failure code [CA145] Coolant Temp Sens Low Error ................................................................................... 42
Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................... 44
Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................ 46
Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................................... 46
Failure code [CA221] Ambient Press Sens High Error ................................................................................. 48
Failure code [CA222] Ambient Press Sens Low Error.................................................................................. 50
Failure code [CA227] Sens Supply 2 Volt High Error ................................................................................... 52
Failure code [CA234] Eng Overspeed .......................................................................................................... 54
Failure code [CA238] Ne Speed Sens Supply Volt Error .............................................................................. 55
Failure code [CA263] Fuel Temp Sensor High Error .................................................................................... 56
Failure code [CA265] Fuel Temp Sensor Low Error ..................................................................................... 58
Failure code [CA271] IMV/PCV1 Short Error................................................................................................ 59
Failure code [CA272] IMV/PCV1 Open Error ............................................................................................... 60
Failure code [CA273] PCV2 Short Error ....................................................................................................... 61
Failure code [CA274] PCV2 Open Error....................................................................................................... 62
2 PC600-8
PC600-8 3
Troubleshooting by failure code (Display of code),

Part 1
Failure code table
Action Failure Alarm Component Category of

Trouble (Displayed on screen)
code code buzzer in charge record
Mechanical
— A000N1 Eng. Hi Out of Std MON
system
Mechanical
— AA10NX Aircleaner Clogging MON
system
Mechanical
— AB00KE Charge Voltage Low MON
system
Mechanical
— B@BAZG Eng. Oil Press. Low MON
system
Mechanical
— B@BAZK Eng. Oil Level Low MON
system
Mechanical
— B@BCNS Eng. Water Overheat MON
system
Mechanical
— B@BCZK Eng. Water Lvl Low MON
system
Mechanical
— B@HANS Hydr. Oil Overheat MON
system
Electrical
E10 CA111 ECM Critical Internal Failure ENG
system
Electrical
E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG
system
Electrical
E11 CA122 Chg Air Press Sensor High Error q ENG
system
Electrical
E11 CA123 Chg Air Press Sensor Low Error q ENG
system
Electrical
E14 CA131 Throttle Sensor High Error q ENG
system
Electrical
E14 CA132 Throttle Sensor Low Error q ENG
system
Electrical
E15 CA135 Eng Oil Press Sensor High Error q ENG
system
Electrical
E15 CA141 Eng Oil Press Sensor Low Error q ENG
system
Electrical
E15 CA144 Coolant Temp Sens High Error q ENG
system
Electrical
E15 CA145 Coolant Temp Sens Low Error q ENG
system
Electrical
E15 CA153 Chg Air Temp Sensor High Error q ENG
system
Electrical
E15 CA154 Chg Air Temp Sensor Low Error q ENG
system
Electrical
E15 CA187 Sens Supply 2 Volt Low Error q ENG
system
Electrical
E15 CA221 Ambient Press Sens High Error q ENG
system
Electrical
E15 CA222 Ambient Press Sens Low Error q ENG
system
Electrical
E15 CA227 Sens Supply 2 Volt High Error q ENG
system
Mechanical
— CA234 Eng Overspeed ENG
system
Electrical
E03 CA238 Ne Speed Sens Supply Volt Error q ENG
system
Electrical
E15 CA263 Fuel Temp Sensor High Error q ENG
system
4 PC600-8

Electrical
E15 CA265 Fuel Temp Sensor Low Error q ENG
system
Electrical
E11 CA271 IMV/PCV1 Short Error q ENG
system
Electrical
E11 CA272 IMV/PCV1 Open Error q ENG
system
Electrical
E11 CA273 PCV2 Short Error q ENG
system
Electrical
E11 CA274 PCV2 Open Error q ENG
system
Electrical
E11 CA322 Inj #1(L#1) Open/Short Error q ENG
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
E10 CA342 Calibration Code Incompatibility ENG
system
Electrical
E10 CA351 Injectors Drive Circuit Error q ENG
system
Electrical
E15 CA352 Sens Supply 1 Volt Low Error q ENG
system
Electrical
E15 CA386 Sens Supply 1 Volt High Error q ENG
system
Electrical
E10 CA441 Battery Voltage low error q ENG
system
Mechanical
E10 CA442 Battery Voltage high error q ENG
system
Electrical
E11 CA449 Rail Press Very High Error q ENG
system
Electrical
E11 CA451 Rail Press Sensor High Error q ENG
system
Electrical
E11 CA452 Rail Press Sensor Low Error q ENG
system
Electrical
E15 CA553 Rail Press High Error q ENG
system
Electrical
— CA554 Rail Press Sensor In Range Error ENG
system
Electrical
E15 CA559 Rail Press Low Error q ENG
system
Electrical
E11 CA689 Eng Ne Speed Sensor Error q ENG
system
Electrical
E15 CA691 Intake Air Temp Sens High Error q ENG
system
Electrical
E15 CA692 Intake Air Temp Sens Low Error q ENG
system
Electrical
E15 CA697 ECM Int Temp Sensor High Error q ENG
system
Electrical
E15 CA698 ECM Int Temp Sensor Low Error q ENG
system
Electrical
E11 CA731 Eng Bkup Speed Sens Phase Error q ENG
system
Electrical
E10 CA757 All Persistent Data Lost Error q ENG
system
PC600-8 5

Electrical
E11 CA778 Eng Bkup Speed Sensor Error q ENG
system
Electrical
E10 CA1117 Persistent Data Lost Error ENG
system
Electrical
E15 CA1228 EGR Valve Servo Error 1 q ENG
system
Electrical
E11 CA1625 EGR Valve Servo Error 2 q ENG
system
Electrical
E11 CA1626 BP Valve Sol Current High Error q ENG
system
Electrical
E11 CA1627 BP Valve Sol Current Low Error q ENG
system
Electrical
E15 CA1628 Bypass Valve Servo Error 1 q ENG
system
Electrical
E11 CA1629 Bypass Valve Servo Error 2 q ENG
system
Electrical
E11 CA1631 BP Valve Pos Sens High Error q ENG
system
Electrical
E11 CA1632 BP Valve Pos Sens Low Error q ENG
system
Electrical
E0E CA1633 KOMNET Datalink Timeout Error q ENG
system
Electrical
E11 CA1642 EGR Inlet Press Sens Low Error q ENG
system
Electrical
E11 CA1653 EGR Inlet Press Sens High Error q ENG
system
Electrical
E14 CA2185 Throt Sens Sup Volt High Error q ENG
system
Electrical
E14 CA2186 Throt Sens Sup Volt Low Error q ENG
system
Electrical
E11 CA2249 Rail Press Very Low Error q ENG
system
Electrical
E11 CA2271 EGR Valve Pos Sens High Error q ENG
system
Electrical
E11 CA2272 EGR Valve Pos Sens Low Error q ENG
system
Electrical
E11 CA2351 EGR Valve Sol Current High Error q ENG
system
Electrical
E11 CA2352 EGR Valve Sol Current Low Error q ENG
system
Electrical
E15 CA2555 Grid Htr relay Volt Low Error q ENG
system
Electrical
E15 CA2556 Grid Htr relay Volt High Error q ENG
system
Electrical
— D110KB Battery Relay Drive S/C PUMP
system
Electrical
— D163KB Flash Light Relay S/C PUMP
system
Electrical
— D195KB Step Light Relay S/C PUMP
system
Electrical
— DA25KP Press. Sensor Power Abnormality PUMP
system
Electrical
— DA2SKQ Model selection Abnormality PUMP
system
Mechanical
— DA80MA Auto. Lub. Abnormal PUMP
system
Electrical
E0E DA2RMC Pump Comm. Abnormality q PUMP
system
Electrical
E0E DAFRMC Monitor Comm. Abnormality q PUMP
system
6 PC600-8

Electrical
— DGE5KY Ambi. Temp. Sensor S/C PUMP
system
Electrical
— DGH2KB Hydr. Oil Temp. Sensor S/C PUMP
system
Electrical
— DHPAMA F Pump P.Sensor Abnormality PUMP
system
Electrical
— DHPBMA R Pump P.Sensor Abnormality PUMP
system
Electrical
— DV20KB Travel Alarm S/C PUMP
system
Electrical
— DW43KA Travel Speed Sol. Disc. PUMP
system
Electrical
— DW43KB Travel Speed Sol. S/C PUMP
system
Electrical
E03 DW45KA Swing Brake Sol. Disc. q PUMP
system
Electrical
E03 DW45KB Swing Brake Sol. S/C q PUMP
system
Electrical
— DW48KA CO Cancel Sol. Disc. PUMP
system
Electrical
— DW48KB CO Cancel Sol. S/C PUMP
system
Electrical
— DW7BKA Fan Reverse Sol. Disc. PUMP
system
Electrical
— DW7BKB Fan Reverse Sol. S/C PUMP
system
Electrical
— DW4XKA Bucket Curl Hi Cancel Sol. Disc. PUMP
system
Electrical
— DW4XKB Bucket Curl Hi Cancel Sol. S/C PUMP
system
Electrical
— DWK0KA 2-stage Relief Sol. Disc. PUMP
system
Electrical
— DWK0KB 2-stage Relief Sol. S/C PUMP
system
Electrical
E11 DX16KA Fan Pump EPC Sol. Disc. q PUMP
system
Electrical
E11 DX16KB Fan Pump EPC Sol. S/C q PUMP
system
Electrical
E02 DXA0KA TVC Sol. Disc. q PUMP
system
Electrical
E02 DXA0KB TVC Sol. S/C q PUMP
system
Electrical
— DY20KA Wiper Working Abnormality PUMP
system
Electrical
— DY20MA Wiper Parking Abnormality PUMP
system
Electrical
— DY2CKB Washer Drive S/C PUMP
system
Electrical
— DY2DKB Wiper Drive (For) S/C PUMP
system
Electrical
— DY2EKB Wiper Drive (Rev) S/C PUMP
system
PC600-8 7
Before carrying out troubleshooting of displayed failure code
Connection table of circuit breakers

a This connection table shows the devices to which each power supply of the circuit breakers supplies power
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting for a displayed code, you should check the circuit breakers to see if the
power is supplied normally.
Type of power Circuit breaker Circuit breaker

Destination of power
supply No. capacity
1 40A Fuse box (Fuses No. 1 – 15)
Switch power 2 20A Boom working lamp, right headlamp
supply
3 20A Grease pump
(Battery relay
terminal M) 4 20A Pump controller power source
5 20A Head lamp on cab
Constant power 6 20A Starting switch, Pump controller (Power supply for solenoid)
supply 7 30A Engine controller (Power supply drive)
(Battery relay 8 20A Machine monitor, Buzzer
terminal B) 9 20A Fuse box (Fuses No. 16 – 20)
8 PC600-8
Connection table of fuse boxes

a This connection table shows the devices to which each power supply of the fuse boxes supplies power (A
switch power supply is a device which supplies power while the starting switch is at the ON position and a
constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting for a displayed code, you should check the fuse boxes to see if the
Type of power
Fuse No. Fuse capacity Destination of power
supply
TVC solenoid (for emergency pump drive)
1 10A
Swing holding brake solenoid (for swing brake release)
2 10A Boom stabilizer solenoid
Switch power PPC lock solenoid
3 10A
supply Starting motor cut-out relay
(Circuit breaker 1) Cigarette lighter
4 20A
Windshield washer motor
Horn
5 10A
Flash light
6 10A Intake air heater
Switch power 7 10A Rotary lamp
supply 8 10A (Spare)
(Circuit breaker 1) 9 10A Radio, Power max. switch
10 20A Machine monitor, Buzzer
11 25A Air conditioner unit
Switch power 12 20A (Spare)
(Circuit breaker 1) 14 10A Service power supply (M32 connector)
15 10A DC/DC converter (12 V)
16 10A Radio backup
17 10A (Spare)
Constant power 18 10A (Spare)
supply 19 10A Room lamp
(Circuit breaker 9) Step light
20 10A Pump controller power source (for step light)
Step light switch
PC600-8 9
Information contained in troubleshooting table
a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-
tents fully before proceeding to actual troubleshooting work.
Action Code Failure Code

Failure
Display in Display in Title of failure phenomenon shown in abnormality record
phenomenon
monitor panel monitor panel
Failure content Failure status as detected by machine monitor or controller
Response from
Action taken by the machine monitor or controller to protect an affected system or equipment, when they
machine moni-
detect some failure.
tor or controller
Phenomenon
Phenomenon that occurs on the machine, resulting from the above action taken by the machine monitor
occurring on
or controller
machine
Relative
Information on the failure occurred as well as the troubleshooting
information
Cause Standard value in normalcy and references for troubleshooting

<Content Included>
• Standard value in normalcy by which to pass "Good" or "No good" judgement over
the presumed cause
1
• Reference for passing the above "Good" or "No Good" judgement
<Phenomenon of Wiring Harness Failure>

• Disconnection
There is a faulty contact at the connector or disconnection of wiring harness
occurred.
2 • Grounding fault
A wiring harness that is not connected with a grounding circuit has a contact with
standard value in normalcy
the grounding circuit.

Presumed cause and
• Hot short
Cause for presumed Wiring harness which is not connected to power source (24 V) circuit is in contact
failure with power source (24 V) circuit.
3 (The attached No. for
filing and reference <Precaution for Troubleshooting>
purpose only. It does not 1) Connector No. display method and handling of T-adapter
stand for any priority) Insert or connect T-adapters in the following manner before starting troubleshoot-
ing unless otherwise instructed.
• If there is no indication of "male" or "female" in a specific connector No., discon-
4 nect the connector and insert the T-adapter into both male and female sides.
• If there is an indication of "male" or "female" in a specific connector No., discon-
nect the connector and connect the T-adepter with only one side of either "male"
or "female".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the
following manner unless otherwise instructed.
5 • Connect the positive (+) lead with the pin No. indicated at the front or the wiring
harness.
• Connect the negative (–) lead with the pin No. indicated at the rear or the wiring
harness.
10 PC600-8
Related circuit diagram
This drawing is a part of the electric circuit diagram related to

troubleshooting.
• Connector No.: Indicates (Model – Number of pins) and
(Color).
• "Connector No. and pin No." from each branching/merging
point: Shows the ends of branch or source of merging within
the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the machine.
PC600-8 11
12 PC600-8
Failure code [A000N1] Eng. Hi Out of Std

Action code Failure code Failure Eng. Hi Out of Std
— A000N1 phenomenon (Mechanical system)
Failure content • Engine speed higher than 2,500 rpm is detected while the engine is running.
Response from
• None in particular.
controller
Phenomenon
occurring on • If the machine is used as it is, the engine may be damaged.
machine
Relative • Input from the engine speed sensor (rpm) can be checked in the monitoring function.
information (Code No. 01002: Engine speed)

Engine overrun Check for external and internal causes for abnormal rise of the engine high idling
1
(While system is normal) speed, then carry out troubleshooting for the mechanical system of the engine.
Presumed cause and
Engine Ne sensor system

2 If failure code [CA238] is displayed, carry out troubleshooting for it.
defective
Engine G sensor system
3 If failure code [CA778] is displayed, carry out troubleshooting for it.
defective
a Turn the engine starting switch ON for the preparations, and keep the engine
running during the troubleshooting.
Engine controller
4 Monitoring Engine Engine speed
defective
010006
High idle 1,900 – 2,000 rpm
Engine speed
PC600-8 13
Failure code [AA10NX] Aircleaner clogging

Action code Failure code Failure Aircleaner clogging
— AA10NX phenomenon (Mechanical system)
• The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine
Failure content
is running.
Response from
controller
Phenomenon
machine
• If the air cleaner clogging monitor on the machine monitor lights up in red while the engine is running,
Relative this failure code is recorded.
information • Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function.
(Code No. 04501: Monitor input 1)

Air cleaner clogged
1 Check the air cleaner. If it is clogged, clean or replace it.
(While system is normal)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position or keep the engine running during the troubleshooting.
Air cleaner clogging
2 switch defective P23 (male) Air cleaner Resistance value
(Internal disconnection) Normal Max. 1 z

Presumed cause and
Between (1) and (2)

Clogged Min. 1 Mz
Disconnection of wiring position during the troubleshooting.
harness
Wiring harness between CM02 (female) (5) and P23 Resistance
3 (Disconnection or defec- Max. 1 z
(female) (1) value
tive contact with connec-
tor) Resistance
Wiring harness between P23 (female) (2) and grounding Max. 1 z
value
position or keep the engine running during the troubleshooting.
4 Monitor panel defective CM02 Air cleaner Voltage
Normal Max. 1 V
Between (5) and grounding
Clogged 20 – 30 V
14 PC600-8
Electrical circuit diagram related to air cleaner clogging switch
PC600-8 15
Failure code [AB00KE] Charge Voltage Low

Action code Failure code Failure Charge Voltage Low
— AB00KE phenomenon (Mechanical system)
Failure content • Signal voltage from alternator is Max. 20 V while the engine is running.
Response from
controller
Phenomenon
occurring on • If the machine is used as it is, the battery may not be charged.
machine
• If the charge level monitor on the machine monitor lights up in red while the engine is running, this fail-
Relative ure code is recorded.
information • Input from the alternator (Voltage, ON or OFF) can be checked in the monitoring function.
(Code No. 04300: Charge voltage, 04501: Monitor input 2)

a Turn the engine starting switch OFF for the preparations, and keep the engine
Alternator defective Alternator Engine Voltage
1
(Internal defect) Between terminal R
Above low idling 27.5 – 29.5 V
and grounding
If the voltage is abnormal, check the belt tension too.
Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.

Presumed cause and
2 (Disconnection or defec-
tive contact with connec- Wiring harness between CM02 (female) (11) and alter- Resistance
Max. 1 z
tor) nator terminal R value
position during the troubleshooting.
Grounding fault of wiring
harness Between wiring harness between CM02 (female) (11)
3 and alternator terminal R, or between P02 (female) (11),
(Contact with grounding Resistance
circuit) D01, J01, and starting switch terminal BR, or between Min. 1 Mz
value
CM02 (female) (11), battery relay terminal BR and
grounding
4 Machine monitor defective CM02 Engine Voltage
Between (11) and
Above low idle 27.5 – 29.5 V
grounding
16 PC600-8
Electrical circuit diagram related to engine preheating, starting, charging
PC600-8 17
Failure code [B@BAZG] Eng. Oil Press. Low

Action code Failure code Failure Eng. Oil Press. Low
— B@BAZG phenomenon (Mechanical system)
Failure content • Signal voltage from engine oil pressure sensor is Max. 0.3 V or Min. 4.42 V.
Response from • Assumes pressure to be 0 MPa {0 kg/cm2} and continues control.
controller • If cause of failure disappears, system resets itself.
Phenomenon
occurring on
machine
Relative • Input state (Pressure) from engine oil pressure sensor can be checked with monitoring function.
information (Code 37200: Engine oil pressure)

Defective sensor power
1 If failure code [CA227] is also displayed, carry out troubleshooting for it first.
supply system
a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective pressure sensor POIL Source voltage
2
(Internal defect) Between (1) – (2) 4.5 – 5.5 V
Between (3) – (2) 0.5 – 4.5 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Disconnection in wiring Wiring harness between ENG (female) (13) – POIL
harness Resistance Max. 1 z
(female) (3)
3 (Disconnection in wiring
Wiring harness between ENG (female) (37) – POIL
Presumed cause and
or defective contact in Resistance Max. 1 z

connector) (female) (1)
Resistance Max. 1 z
(female) (2)
Ground fault in wiring starting switch ON.
4 harness
(Contact with GND circuit) Wiring harness between ENG (female) (13) – POIL
Resistance Min. 1 Mz
(female) (3)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Hot short (Short circuit
5 with 24V circuit) in wiring Voltage Max. 1 V
(female) (3)
harness
Voltage Max. 1 V
(female) (1)
a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
ENG CE01 Voltage
6 Defective engine controller
Between (37) – (47) 4.5 – 5.5 V
Between (13) – (47) 0.5 – 4.5 V
18 PC600-8
Electrical circuit diagram related to Eng. Oil Press. Low
PC600-8 19
Failure code [B@BAZK] Eng. Oil Level Low

Action code Failure code Failure Eng. Oil Level Low
— B@BAZK phenomenon (Mechanical system)
• The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the
Failure content
engine is stopped.
Response from
controller
Phenomenon
machine
• If the engine oil level monitor on the machine monitor lights up in red while the engine is running, this
Relative failure code is recorded.
information • Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function.

Engine oil level low Check the oil level in the engine oil pan. If it is low, add oil. (If it is reduced fre-
1
(While system is normal) quently, find out the cause.)
Engine oil level switch
2 defective P44 (male) Engine oil level Resistance value

Presumed cause and
(Internal disconnection) Normal level Max. 1 z

Below normal level Min. 1 Mz
tive contact with connec- Wiring harness between CM02 (female) (8) and P44 Resistance
Max. 1 z
tor) (female) (1) value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
4 Machine monitor defective CM02 Engine oil level Voltage
Normal level Max. 1 V
Below normal level 20 – 30 V
Electrical circuit diagram related to engine oil level switch
20 PC600-8
Failure code [B@BCNS] Eng. Water Overheat

Action code Failure code Failure Eng. Water Overheat
— B@BCNS phenomenon (Mechanical system)
Failure content • The signal circuit of the engine water high temperature sensor detected temperature above 105°C.
Response from
controller
Phenomenon
machine
• If the engine coolant temperature monitor on the machine monitor lights up in red while the engine is
running, this failure code is recorded.
Relative
• Input from the engine coolant high temperature sensor (coolant temperature and voltage) can be
information
checked in the monitoring function. (Code No. 04107: Engine coolant temperature, 04105: Engine
coolant temperature sensor voltage)

Engine overheated Check the engine for overheating. If it has been overheated, find out the cause and
1
Presumed cause and
(While system is normal) check the engine for damage, then repair.
Engine coolant
Carry out troubleshooting for "E-12 Display of engine coolant temperature gauge on
2 temperature sensor
machine monitor is abnormal" in E-mode.
system defective
Engine controller position during the troubleshooting.
3
defective ENG (female) Engine water temperature Resistance value
Between (15) and (38) 105°C 3.28 kz
Electrical circuit diagram related to engine coolant temperature sensor
PC600-8 21
Failure code [B@BCZK] Eng. Water Lvl Low

Action code Failure code Failure Eng. Water Lvl Low
— B@BCZK phenomenon (Mechanical system)
• The signal circuit of the radiator coolant level switch is opened (disconnected from grounding) while the
Failure content
engine is running.
Response from
controller
Phenomenon
occurring on • If the machine is used as it is, the engine will overheat.
machine
• If the radiator coolant level monitor on the machine monitor lights up in red while the engine is stopped
Relative (the starting switch is at the ON position), this failure code is recorded.
information • Input from the radiator water level switch (ON or OFF) can be checked in the monitoring function.

Sub-tank coolant level low Check the radiator sub-tank coolant level. If it is low, add coolant. (If it is reduced fre-
1
(While system is normal) quently, find out the cause.)
Radiator coolant level
2 switch defective P24 (male) Sub-tank coolant level Resistance value
(Internal disconnection) Within normal level Max. 1 z

Presumed cause and
Between (1) and (2)

Below LOW level Min. 1 Mz
harness
(female) (1) value
tor) Resistance
value
4 Machine monitor defective CM02 Sub-tank coolant level Voltage
Within normal level Max. 1 V
Below LOW level 20 – 30 V
22 PC600-8
Electrical circuit diagram related to radiator coolant level switch
PC600-8 23
Failure code [B@HANS] Hydr. Oil Overheat

Action code Failure code Failure Hydr. Oil Overheat
— B@HANS phenomenon (Mechanical system)
Failure content • The signal of the hydraulic oil temperature sensor rises above 102°C while the engine is running.
Response from
controller
Phenomenon
occurring on • If the machine is used as it is, the hydraulic equipment may be damaged.
machine
• If the hydraulic oil temperature monitor on the machine monitor lights up in red while the engine is run-
Relative ning, this failure code is recorded.
information • Input from the hydraulic oil temperature sensor can be checked in the monitoring function.
(Code No. 04401: Hydraulic oil temperature, 04402: Hydraulic oil temperature sensor voltage)

Hydraulic oil overheated Check the hydraulic oil for overheating. If it has been overheated, find out the cause
1
(While system is normal) and check the hydraulic equipment for damage, then repair.
Hydraulic oil temperature
P22 (male) Hydraulic oil temperature Resistance value
2 sensor defective
Presumed cause and
(Internal short-circuiting) Between (1) and (2) 90 – 3.5 kz

10 – 100°C
Between (1) and grounding Min. 1 Mz
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
3
(Contact with grounding Between wiring harness between CM02 (female) (12) Resistance
circuit) Min. 1 Mz
and P22 (female) (1) and grounding value
CM02 Hydraulic oil temperature Resistance value
4 Machine monitor defective
Between (12) and (13) 90 – 3.5 kz
Between (12) and 10 – 100°C
Min. 1 Mz
grounding
Electrical circuit diagram related to hydraulic oil temperature sensor
24 PC600-8
Failure code [CA111] ECM Critical Internal Failure
Action code Failure code ECM Critical Internal Failure

Trouble
E10 CA111 (Engine controller system)
Contents of trouble • Abnormality occurred in controller.
Action of controller • None in particular.
Problem that appears
• Engine runs normally but it may stop during operation or may not be able to start.
on machine
Related information —
Cause Standard value in normal state/Remarks on troubleshooting

Check circuit breaker No.7 directly for defect.
1 Defective circuit breaker No.7
(If circuit breaker is turned OFF, circuit probably has ground fault.)
a Prepare with starting switch OFF, then carry out trouble-
Disconnection in wiring har- shooting without turning starting switch ON.
ness (Disconnection in wir- Wiring harness between CE03
2 Resistance Max. 1 z
ing or defective contact in (female) (3) – battery (+)
connector) Wiring harness between CE03
Possible causes and Resistance Max. 1 z
standard value in nor- (female) (1) – chassis ground
mal state a Prepare with starting switch OFF, then carry out trouble-
Ground fault in wiring har- shooting without turning starting switch ON.
3 ness (Short circuit with GND
circuit) Wiring harness between CE03
Resistance Max. 1 z
(female) (3) – battery (+)
a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
CE03 Voltage
Between (3) – (1) 20 – 30 V
Circuit diagram related to controller power supply
PC600-8 25
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Action code Failure code Eng Ne and Bkup Speed Sens Error
Trouble
Contents of trouble • Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
Problem that appears • Engine cannot be started (if engine has been stopped).
on machine • Engine stops (if engine has been running).
Related information

Defective Ne speed sensor
1 Carry out troubleshooting for Failure code [CA689].
system
Defective Bkup speed sen-
2 Carry out troubleshooting for Failure code [CA778].
sor system
Defective mount of Ne Check mount of Ne speed sensor directly for defect (defective
Possible causes and 3
speed sensor installation of sensor, internal trouble of flywheel, etc.)
standard value in nor-
mal state Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defec-
4
speed sensor tive installation of sensor, internal trouble of supply pump, etc.)
Defective connection Check Ne speed sensor and Bkup speed sensor directly for
5
(Wrong connection) defective connection (wrong connection).
If causes 1 – 5 are not detected, engine controller may be
6 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
26 PC600-8
PC600-8 27
Failure code [CA122] Chg Air Press Sensor High Error
Action code Failure code Chg Air Press Sensor High Error
Trouble
Contents of trouble • Signal voltage in charge pressure sensor circuit is abnormally high.
Action of controller • Fixes charge pressure (400 kPa {4.1 kg/cm2}) and continues operation.
• Acceleration performance of engine drops.
on machine
• Signal voltage of boost pressure sensor can be checked with monitoring function.
Related information
(Code: 36501 Boost pressure sensor voltage)

Defective sensor power If failure code [CA187] or [CA227] is indicated, carry out trouble-
1
supply system shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
Defective charge pres- PIM Voltage
2 sure sensor (Internal Between (1) – (2) Power supply 4.75 – 5.25 V
trouble)
Pressure sensor voltage is measured with wiring harness con-
nected. Accordingly, if voltage is abnormal, check wiring harness
and controller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Disconnection in wiring Wiring harness between ENG (female)
Resistance Max. 1 z
harness (Disconnection (37) – PIM (female) (1)
3
in wiring or defective con- Wiring harness between ENG (female)
tact in connector) Resistance Max. 1 z
(47) – PIM (female) (2)
Wiring harness between ENG (female)
Resistance Max. 1 z
(44) – PIM (female) (3)
Possible causes and ing without turning starting switch ON.
standard value in nor- Wiring harness between ENG (female)
mal state Ground fault in wiring Resistance Min. 1 Mz
(37) – PIM (female) (1)
4 harness (Short circuit
with GND circuit) Wiring harness between ENG (female)
(47) – PIM (female) (2)
(44) – PIM (female) (3)
(37) – PIM (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (47) – PIM (female) (2)
5 ness (with another wiring Wiring harness between ENG (female)
harness) (37) – PIM (female) (1) and between Resistance Min. 1 Mz
ENG (female) (44) – PIM (female) (3)
(47) – PIM (female) (2) and between Resistance Min. 1 Mz
ENG (female) (44) – PIM (female) (3)
Defective engine control- or start engine and carry out troubleshooting.
6
ler ENG Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
28 PC600-8
Circuit diagram related to charge pressure sensor
PC600-8 29
Failure code [CA123] Chg Air Press Sensor Low Error
Action code Failure code Chg Air Press Sensor Low Error
Trouble
Contents of trouble • Signal voltage in charge pressure sensor circuit is abnormally low.
Action of controller • Fixes charge pressure (400 kPa {4.1 kg/cm2}) and continues operation.
• Acceleration performance of engine drops.
on machine
• Signal voltage of boost pressure sensor can be checked with monitoring function.
Related information
(Code: 36501 Boost pressure sensor voltage)
Possible causes and Cause Standard value in normal state/Remarks on troubleshooting

mal state Carry out troubleshooting for failure Code [CA122].
30 PC600-8
PC600-8 31
Failure code [CA131] Throttle Sensor High Error
Action code Failure code Throttle Sensor High Error

Trouble
Contents of trouble • Throttle sensor circuit has high error.
• Continues operation by setting throttle angle with signal other than throttle sensor signal.
Action of controller • If this error is detected while engine is running, controller keeps signal of fuel control dial just
before error is detected.
• Engine speed may not be controlled.
on machine
• Signal voltage of fuel control dial can be checked with monitoring function.
Related information
(Code: 03000 Fuel control dial voltage)

Defective sensor power If failure code [CA2185] or [CA2186] is also displayed, carry
1
supply system out troubleshooting for it first.
shooting without turning starting switch ON.
Defective fuel control dial P20 (male) Resistance

2
(Internal defect) Between (1) – (3) 4.0 – 6.0 kz
Between (2) – (1) 0.25 – 5.0 kz
Between (2) – (3) 0.25 – 5.0 kz
Disconnection in wiring har- Wiring harness between CE02
Resistance Max. 1 z
ness (Disconnection in wir- (female) (22) – P20 (female) (1)
3
ing or defective contact in Wiring harness between CE02
Possible causes and connector) Resistance Max. 1 z
(female) (9) – P20 (female) (2)
mal state Wiring harness between CE02
Resistance Max. 1 z
Wiring harness between CE02
Ground fault in wiring har- (female) (22) – P20 (female) (1) Resistance Min. 1 Mz
4 ness (Contact with GND cir-
cuit) Wiring harness between CE02
5 Defective engine controller CE02 Voltage
Between (9) – (23) Signal 0.5 – 4.5 V
32 PC600-8
Circuit diagram related to throttle sensor of fuel control dial type
PC600-8 33
Failure code [CA132] Throttle Sensor Low Error
Action code Failure code Throttle Sensor Low Error

Trouble
Contents of trouble • Signal voltage in throttle sensor circuit is abnormally low.
Action of controller • Sets throttle angle with signal other than throttle signal and continues operation.
—
on machine
• If this error is detected while engine is running, controller keeps signal of fuel control dial just
Related information before error is detected.
(Code: 03000 Fuel control dial voltage)

mal state Carry out troubleshooting for failure Code [CA131].
34 PC600-8
PC600-8 35
Failure code [CA135] Eng Oil Press Sensor High Error
Action code Failure code Eng Oil Press Sensor High Error
Trouble
Contents of trouble • Signal voltage in oil pressure sensor circuit is abnormally high.
Action of controller • Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
—
on machine
• Signal voltage of oil pressure sensor can be checked with monitoring function.
Related information
(Code: 37201 Oil pressure sensor voltage)

1
POIL Voltage
Defective oil pressure
2 Between (1) – (2) Power supply 4.75 – 5.25 V
sensor (Internal trouble)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
Resistance Max. 1 z
harness (Disconnection (37) – POIL (female) (1)
3
(47) – POIL (female) (2)
Resistance Max. 1 z
(37) – POIL (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (47) – POIL (female) (2)
harness) (37) – POIL (female) (1) and between Resistance Min. 1 Mz
ENG (female) (13) – POIL (female) (3)
(47) – POIL (female) (2) and between Resistance Min. 1Mz
ENG (female) (13) – POIL (female) (3)
5
ler ENG Voltage
36 PC600-8
Circuit diagram related to oil pressure sensor
PC600-8 37
Failure code [CA141] Eng Oil Press Sensor Low Error
Action code Failure code Eng Oil Press Sensor Low Error
Trouble
Contents of trouble • Signal voltage in oil pressure sensor circuit is abnormally low.
Action of controller • Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
—
on machine
• Signal voltage of oil pressure sensor can be checked with monitoring function.
Related information
(Code: 37201 Oil pressure sensor voltage)

mal state Carry out troubleshooting for failure code [CA135].
38 PC600-8
PC600-8 39
Failure code [CA144] Coolant Temp Sens High Error
Action code Failure code Coolant Temp Sens High Error

Trouble
Contents of trouble • Signal voltage in coolant temperature sensor circuit is abnormally high.
Action of controller • Fixes coolant temperature (90°C) and continues operation.
—
on machine
• Signal voltage of coolant temperature sensor can be checked with monitoring function.
Related information
(Code: 04105 Coolant temperature sensor voltage)

Defective coolant tempera- shooting without turning starting switch ON.
1 ture sensor (Internal trou- Coolant
TWTR (male) Resistance
ble) temperature
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
ness (Disconnection in wir- Wiring harness between ENG
ing or defective contact in (female) (15) – TWTR (female) (A)
Possible causes and connector)
standard value in nor- Wiring harness between ENG
Resistance Max. 1 z
mal state (female) (38) – TWTR (female) (B)
3 ness (Short circuit with GND Wiring harness between ENG
circuit) (female) (15) – TWTR (female) (A) Resistance Min. 1 Mz
and chassis ground
4 Defective engine controller Coolant
ENG (female) Resistance
temperature
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
40 PC600-8
Circuit diagram related to coolant temperature sensor
PC600-8 41
Failure code [CA145] Coolant Temp Sens Low Error
Action code Failure code Coolant Temp Sens Low Error

Trouble
Contents of trouble • Signal voltage in coolant temperature sensor circuit is abnormally low.
Action of controller • Fixes coolant temperature (90°C) and continues operation.
—
on machine
• Signal voltage of coolant temperature sensor can be checked with monitoring function.
Related information
(Code: 04105 Coolant temperature sensor voltage)

42 PC600-8
PC600-8 43
Failure code [CA153] Chg Air Temp Sensor High Error
Action code Failure code Chg Air Temp Sensor High Error
Trouble
Contents of trouble • Signal voltage in charge temperature sensor circuit is abnormally high.
Action of controller • Fixes charge temperature (intake air temperature) (70°C) and continues operation.
—
on machine
• Signal voltage of boost temperature sensor can be checked with monitoring function.
Related information
(Code: 18501 Boost temperature sensor voltage)

Defective charge tempera- Intake air
TIM (male) Resistance
1 ture sensor temperature
(Internal trouble) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) –
All range Min. 1 Mz
chassis ground
Possible causes and ness (Disconnection in wir- Wiring harness between ENG
standard value in nor- ing or defective contact in (female) (23) – TIM (female) (A)
mal state connector) Wiring harness between ENG
Resistance Max. 1 z
(female) (47) – TIM (female) (B)
circuit) Wiring harness between ENG
(female) (23) – TIM (female) (A)
4 Defective engine controller Intake air
temperature
Between (23) – (47) 10 – 100°C 0.5 – 20 kz
44 PC600-8
Circuit diagram related to charge temperature sensor
PC600-8 45
Failure code [CA154] Chg Air Temp Sensor Low Error
Action code Failure code Chg Air Temp Sensor Low Error
Trouble
Contents of trouble • Signal voltage in charge temperature sensor circuit is abnormally low.
Action of controller • Fixes charge temperature (intake air temperature) (70°C) and continues operation.
—
on machine
• Signal voltage of boost temperature sensor can be checked with monitoring function.
Related information
(Code: 18501 Boost temperature sensor voltage)

Failure code [CA187] Sens Supply 2 Volt Low Error
Action code Failure code Sens Supply 2 Volt Low Error

Trouble
Contents of trouble • Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
• Operates Bkup speed sensor with signals of Ne speed sensor.
• Sets oil pressure sensor to default value (250 kPa {2.5 kg/cm2}) and continues operation.
• Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues
operation.
Action of controller
• Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
• Sets EGR inlet pressure sensor to default value (102 kPa {1.0 kg/cm2}) and continues operation.
• Limits output of EGR valve lift sensor and closes EGR valve and bypass valve.
• Limits output of bypass valve lift sensor and closes EGR valve and bypass valve.
• Output drops.
on machine
Related information

46 PC600-8
PC600-8 47
Failure code [CA221] Ambient Press Sens High Error
Action code Failure code Ambient Press Sens High Error

Trouble
Contents of trouble • Signal voltage in atmospheric pressure sensor circuit is abnormally high.
Action of controller • Sets atmospheric pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
• Output drops.
on machine
• Signal voltage of atmospheric pressure sensor can be checked with monitoring function.
Related information
(Code: 37401 Atmospheric pressure sensor voltage)

1
and carry out troubleshooting.
PAMB Voltage
Defective atmospheric
2 pressure sensor (Internal
trouble) Between (3) – (2) Signal
Resistance Max. 1 z
harness (Disconnection (33) – PAMB (female) (1)
3
(38) – PAMB (female) (2)
Resistance Max. 1 z
(33) – PAMB (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (38) – PAMB (female) (2)
harness) (33) – PAMB (female) (1) and between Resistance Min. 1 Mz
ENG (female) (3) – PAMB (female) (3)
(38) – PAMB (female) (2) and between Resistance Min. 1 Mz
ENG (female) (3) – PAMB (female) (3)
Defective engine control- ENG Voltage
6
ler
Between (33) – (38) 4.75 – 5.25 V
Between (3) – (38) —
48 PC600-8
Circuit diagram related to atmospheric pressure sensor
PC600-8 49
Failure code [CA222] Ambient Press Sens Low Error
Action code Failure code Ambient Press Sens Low Error

Trouble
Contents of trouble • Signal voltage in atmospheric pressure sensor circuit is abnormally low.
Action of controller • Sets atmospheric pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
• Output drops.
on machine
• Signal voltage of atmospheric pressure sensor can be checked with monitoring function.
Related information
(Code: 37401 Atmospheric pressure sensor voltage)

50 PC600-8
PC600-8 51
Failure code [CA227] Sens Supply 2 Volt High Error
Action code Failure code Sens Supply 2 Volt High Error

Trouble
Contents of trouble • Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
• Operates Bkup speed sensor with signals of Ne speed sensor.
• Sets oil pressure sensor to default value (250 kPa {2.5 kg/cm2}) and continues operation.
operation.
• Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
• Sets EGR inlet pressure sensor to default value (102 kPa {1.0 kg/cm2}) and continues operation.
• Limits output of EGR valve lift sensor and closes EGR valve and bypass valve.
• Output drops.
on machine

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Bkup speed
G connector
sensor
Oil pressure
POIL connector
sensor
Disconnect devices at Atmospheric
PAMB
Defective sensor right in order. If error pressure sensor
2
(Internal trouble) code disappears when Charge pres-
PIM connector
a device is discon- sure sensor
nected, that device EGR inlet pres-
has a defect in it. PEVA connector
sure sensor
EGR valve lift
SEGR connector
sensor
Common rail
PFUEL connector
pressure sensor
Possible causes and Disconnection in wiring ing without turning starting switch ON.
standard value in nor- harness
mal state Wiring harness between ENG (female)
3 (Disconnection in wiring Resistance Max. 1 z
(37) – each sensor (female)
or defective contact in
connector) Wiring harness between ENG (female)
Resistance Max. 1 z
(47) – each sensor (female)
Ground fault in wiring ing without turning starting switch ON.
harness Wiring harness between ENG (female) (37)
4 Resistance Min. 1 Mz
(Short circuit with GND – each sensor (female) and chassis ground
circuit) Wiring harness between ENG (female) (47)
– each sensor (female) and chassis ground
Short circuit in wiring har- ing without turning starting switch ON.
ness Wiring harness between ENG (female)
5
(with another wiring har- (37) – each sensor (female) and between
ness) Resistance Min. 1 Mz
ENG (female) (47) – each sensor
(female) and chassis ground
Defective engine control- and carry out troubleshooting.
6
ler ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
52 PC600-8
Circuit diagram related to sensor power supply 2 (5 V)
PC600-8 53
Failure code [CA234] Eng Overspeed
Action code Failure code Eng Overspeed

Trouble
— CA234 (Engine controller system)
Contents of trouble • Engine speed is above operating range.
Action of controller • Limits fuel injection rate until engine speed lowers to operating range.
• Engine speed fluctuates.
on machine

Possible causes and
standard value in nor- 2 Improper way of use Way of use may be improper. Teach proper way of use to operator.
mal state If causes 1 – 2 are not detected, engine controller may be
be carried out.)
54 PC600-8
Failure code [CA238] Ne Speed Sens Supply Volt Error
Action code Failure code Ne Speed Sens Supply Volt Error

Trouble
Contents of trouble • Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
Action of controller • Controls Ne speed sensor with signals of Bkup speed sensor.
Problem that appears • Running engine stops (when Bkup speed sensor is also abnormal).
on machine Stopped engine cannot be started (when Bkup speed sensor is also abnormal).

Defective Ne speed sen- Disconnect devices at right

1 in order. If error code disap-
sor (Internal trouble) Ne speed
pears when a device is dis- NE connector
sensor
connected, that device has
a defect in it.
Disconnection in wiring ing without turning starting switch ON.
harness (Disconnection Wiring harness between ENG (female)
in wiring or defective con- (16) – NE (female) (1)
tact in connector) Wiring harness between ENG (female)
Resistance Max. 1 z
(48) – NE (female) (2)
Possible causes and
standard value in nor- a Prepare with starting switch OFF, then carry out troubleshoot-
mal state ing without turning starting switch ON.
Ground fault in wiring
3 harness (Short circuit Resistance Min. 1 Mz
(16) – NE (female) (1)
with GND circuit)
(48) – NE (female) (2)
Short circuit in wiring har- ing without turning starting switch ON.
harness) (16) – NE (female) (1) and between ENG Resistance Min. 1 Mz
(female) (48) – NE (female) (2)
5
ler ENG Voltage
Between (16) – (48) 4.75 – 5.25 V
Circuit diagram related to Ne speed sensor power supply
PC600-8 55
Failure code [CA263] Fuel Temp Sensor High Error
Action code Failure code Fuel Temp Sensor High Error

Trouble
Contents of trouble • Signal voltage in fuel temperature sensor circuit is abnormally high.
Action of controller • Fixes fuel temperature (90°C) and continues operation.
—
on machine
• Signal voltage of fuel temperature sensor can be checked with monitoring function.
Related information
(Code: 14201 fuel temperature sensor voltage)

Defective fuel temperature
1 Fuel
sensor (Internal trouble) TFUEL (male) Resistance
temperature
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Possible causes and ing or defective contact in (female) (30) – TFUEL (female) (A)
standard value in nor- connector) Wiring harness between ENG
mal state Resistance Max. 1 z
(female) (47) – TFUEL (female) (B)
circuit) Wiring harness between ENG
(female) (30) – TFUEL (female) (A)
4 Defective engine controller Fuel
temperature
Between (30) – (47) 10 – 100°C 0.6 – 20 kz
56 PC600-8
Circuit diagram related to fuel temperature sensor
PC600-8 57
Failure code [CA265] Fuel Temp Sensor Low Error
Action code Failure code Fuel Temp Sensor Low Error

Trouble
Contents of trouble • Signal voltage in fuel temperature sensor circuit is abnormally low.
Action of controller • Fixes fuel temperature (90°C) and continues operation.
—
on machine
• Signal voltage of fuel temperature sensor can be checked with monitoring function.
Related information
(Code: 14201 fuel temperature sensor voltage)

58 PC600-8
Failure code [CA271] IMV/PCV1 Short Error
Action code Failure code IMV/PCV1 Short Error

Trouble
Contents of trouble • There is short circuit in PCV1 circuit of supply pump.
—
on machine

Defective supply pump PCV1 (male) Resistance
1
PCV1 (Internal trouble) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
Wiring harness between ENG
Ground fault in wiring har-
(female) (4) – PCV1 (female) (1) and Resistance Min. 1 Mz
chassis ground
circuit)
Possible causes and Wiring harness between ENG
standard value in nor- (female) (5) – PCV1 (female) (2) and Resistance Min. 1 Mz
mal state chassis ground
Hot short (Short circuit with
3 24V circuit) in wiring har- Voltage Max. 1 V
(female) (4) – PCV1 (female) (1)
ness
Voltage Max. 1 V
Between (4) – (5) 2.3 – 5.3 z
Between (4), (5) –
Min. 1 Mz
chassis ground
Circuit diagram related to supply pump PCV1
PC600-8 59
Failure code [CA272] IMV/PCV1 Open Error
Action code Failure code IMV/PCV1 Open Error

Trouble
Contents of trouble • There is disconnection in PCV1 circuit of supply pump.
—
on machine

1 PCV1 (Internal disconnec-
tion) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
ing or defective contact in (female) (4) – PCV1 (female) (1)
connector) Wiring harness between ENG
Resistance Max. 1 z
Possible causes and (female) (5) – PCV1 (female) (2)
standard value in nor- a Prepare with starting switch OFF, then carry out trouble-
mal state shooting without turning starting switch ON.
chassis ground
circuit)
chassis ground
Between (4) – (5) 2.3 – 5.3 z
Between (4), (5) –
Min. 1 Mz
chassis ground
60 PC600-8
Failure code [CA273] PCV2 Short Error
Action code Failure code PCV2 Short Error

Trouble
Contents of trouble • There is short circuit in PCV2 circuit of supply pump.
—
on machine

1
PCV2 (Internal trouble) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
chassis ground
circuit)
Possible causes and (female) (10) – PCV2 (female) (2) and Resistance Min. 1 Mz
standard value in nor- chassis ground
mal state a Prepare with starting switch OFF, then turn starting switch
Hot short (Short circuit with
(female) (9) – PCV2 (female) (1) and Voltage Max. 1 V
3 24V circuit) in wiring har-
chassis ground
ness
(female) (10) – PCV2 (female) (2) and Voltage Max. 1 V
chassis ground
Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
PC600-8 61
Failure code [CA274] PCV2 Open Error
Action code Failure code PCV2 Open Error

Trouble
Contents of trouble • There is disconnection in PCV2 circuit of supply pump.
—
on machine

Defective supply pump shooting without turning starting switch ON.
1 PCV2 (Internal disconnec-
PCV2 (male) Resistance
tion)
Between (1) – (2) 2.3 – 5.3 z
ing or defective contact in (female) (9) – PCV2 (female) (1)
Resistance Max. 1 z
Possible causes and a Prepare with starting switch OFF, then carry out trouble-
standard value in nor- shooting without turning starting switch ON.
mal state
chassis ground
circuit)
chassis ground
Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
62 PC600-8
PC600-8 63
©2006 KOMATSU
All Rights Reserved
64
UEN00449-00
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 K50001 and up

40 Troubleshooting

Failure code [CA322] Inj #1 (L#1) Open/Short Error ...................................................................................... 4
Failure code [CA332] Inj #4 (L#4) Open/Short Error .................................................................................... 10
Failure code [CA342] Calibration Code Incompatibility .................................................................................11
Failure code [CA351] Injectors Drive Circuit Error........................................................................................ 12
Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................................... 15
Failure code [CA386] Sens Supply 1 Volt High Error ................................................................................... 16
Failure code [CA441] Battery Voltage Low Error .......................................................................................... 18
Failure code [CA442] Battery Voltage High Error ......................................................................................... 18
Failure code [CA449] Rail Press Very High Error ......................................................................................... 19
Failure code [CA451] Rail Press Sensor High Error..................................................................................... 20
Failure code [CA452] Rail Press Sensor Low Error ..................................................................................... 22
Failure code [CA553] Rail Press High Error ................................................................................................. 22
Failure code [CA554] Rail Press Sensor In Range Error ............................................................................. 23
Failure code [CA559] Rail Press Low Error .................................................................................................. 24
Failure code [CA689] Eng Ne Speed Sensor Error ...................................................................................... 28
PC600-8 1
Failure code [CA691] Intake Air Temp Sens High Error ............................................................................... 30
Failure code [CA692] Intake Air Temp Sens Low Error ................................................................................ 31
Failure code [CA697] ECM Int Temp Sens High Error.................................................................................. 32
Failure code [CA698] ECM Int Temp Sens Low Error .................................................................................. 32
Failure code [CA731] Eng Bkup Speed Sens Phase Error........................................................................... 33
Failure code [CA757] All Persistent Data Lost Error..................................................................................... 33
Failure code [CA778] Engine Bkup Speed Sensor Error .............................................................................. 34
Failure code [CA1117] Persistent Data Lost Error ........................................................................................ 36
Failure code [CA1228] EGR Valve Servo Error 1 ......................................................................................... 36
Failure code [CA1625] EGR Valve Servo Error 2 ......................................................................................... 37
Failure code [CA1626] BP Valve Sol Current High Error .............................................................................. 38
Failure code [CA1627] BP Valve Sol Current Low Error............................................................................... 40
Failure code [CA1628] Bypass Valve Servo Error 1 ..................................................................................... 40
Failure code [CA1629] Bypass Valve Servo Error 2 ..................................................................................... 41
Failure code [CA1631] BP Valve Pos Sens High Error................................................................................. 42
Failure code [CA1632] BP Valve Pos Sens Low Error ................................................................................. 44
Failure code [CA1633] KOMNET Datalink Timeout Error............................................................................. 46
Failure code [CA1642] EGR Inlet Press Sens Low Error ............................................................................. 48
Failure code [CA1653] EGR Inlet Press Sens High Error............................................................................. 50
Failure code [CA2185] Throt Sens Sup Volt High Error................................................................................ 52
Failure code [CA2186] Throt Sens Sup Volt Low Error ................................................................................ 54
Failure code [CA2249] Rail Press Very Low Error........................................................................................ 54
Failure code [CA2271] EGR Valve Pos Sens High Error.............................................................................. 56
Failure code [CA2272] EGR Valve Pos Sens Low Error .............................................................................. 58
Failure code [CA2351] EGR Valve Sol Current High Error ........................................................................... 60
Failure code [CA2352] EGR Valve Sol Current Low Error............................................................................ 62
Failure code [CA2555] Grid Htr Relay Volt Low Error................................................................................... 62
Failure code [CA2556] Grid Htr Relay Volt High Error.................................................................................. 64
2 PC600-8
PC600-8 3

Part 2
Failure code [CA322] Inj #1 (L#1) Open/Short Error
Action code Failure code Inj #1 (L#1) Open/Short Error

Trouble
Contents of trouble • There is disconnection or short circuit in injector #1 circuit.
• Output drops.
on machine

Defective injector #1 (Inter- CN1 (male) Resistance
1
nal trouble) Between (1) – (2) 0.4 – 1.1 z
Between (1), (2) –
Min. 1M z
chassis ground
ing or defective contact in (female) (45) – CN1 (female) (1)
Resistance Max. 1 z
Possible causes and (female) (53) – CN1 (female) (2)
(female) (45) – CN1 (female) (1) and Resistance Min. 1 Mz
chassis ground
circuit)
chassis ground
Between (45) – (53) 0.4 – 1.1 z
Between (45), (53) –
Min. 1 Mz
chassis ground
4 PC600-8
Circuit diagram related to injector #1
PC600-8 5

Trouble
• Output drops.
on machine
Related information • Different machine models may have different connector Nos.

1
Between (1), (2) –
Min. 1 Mz
chassis ground
Resistance Max. 1 z
chassis ground
circuit)
chassis ground
Between (46) – (60) 0.4 – 1.1 z
Between (46), (60) –
Min. 1 Mz
chassis ground
6 PC600-8

Trouble
• Output drops.
on machine

1
Between (1), (2) – chassis
Min. 1M z
ground
Resistance Max. 1 z
chassis ground
circuit)
chassis ground
Between (55) – (52) 0.4 – 1.1 z
Between (55), (52) –
Min. 1M z
chassis ground
PC600-8 7

Trouble
• Output drops.
on machine

1
Between (1), (2) –
Min. 1 Mz
chassis ground
Resistance Max. 1 z
chassis ground
circuit)
chassis ground
Between (57) – (59) 0.4 – 1.1 z
Between (57), (59) –
Min. 1 Mz
chassis ground
8 PC600-8

Trouble
• Output drops.
on machine

1
Between (1), (2) –
Min. 1 Mz
chassis ground
Resistance Max. 1 z
chassis ground
circuit)
chassis ground
Between (54) – (51) 0.4 – 1.1 z
Between (54), (51) –
Min. 1 Mz
chassis ground
PC600-8 9

Trouble
• Output drops.
on machine

1
Between (1), (2) –
Min. 1 Mz
chassis ground
Resistance Max. 1 z
chassis ground
circuit)
chassis ground
Between (56) – (58) 0.4 – 1.1 z
Between (56), (58) –
Min. 1 Mz
chassis ground
10 PC600-8
Failure code [CA342] Calibration Code Incompatibility
Action code Failure code Calibration Code Incompatibility

Trouble
Contents of trouble • Matching error occurred in engine controller data.
Problem that appears • Engine continues operation normally, but it may stop during operation or may not be able to
on machine start.

PC600-8 11
Failure code [CA351] Injectors Drive Circuit Error
Action code Failure code Injectors Drive Circuit Error

Trouble
Contents of trouble • Abnormality occurred in injector drive circuit.
Action of controller • Limits output and continues operation (Limits common rail pressure).
• Output drops.
on machine

If another failure code (code of abnormality in injector system)
1 Defective related system
is indicated, carry out troubleshooting for it.
Check circuit breaker No.7 directly for defect.
Defective circuit breaker
2 (If circuit breaker is turned OFF, circuit probably has ground
No.7
fault.)
ness (Disconnection in wir- Wiring harness between CE03
ing or defective contact in (female) (3) – battery (+)
connector) Wiring harness between CE03
(female) (1) – chassis ground
mal state a Prepare with starting switch OFF, then carry out trouble-
(female) (3) – battery (+) and chassis Resistance Min. 1 Mz
ground
circuit)
(female) (1) – chassis ground and Resistance Min. 1 Mz
chassis ground
CE03 Voltage
Between (3) – (1) 20 – 30 V
12 PC600-8
Circuit diagram related to controller power supply
PC600-8 13
14 PC600-8
Failure code [CA352] Sens Supply 1 Volt Low Error
Action code Failure code Sens Supply 1 Volt Low Error

Trouble
Contents of trouble • Signal voltage in sensor power supply (5 V) circuit is abnormally low.
• Limits output of common rail pressure sensor and continues operation (Limits common rail
pressure).
• Output drops.
on machine

PC600-8 15
Failure code [CA386] Sens Supply 1 Volt High Error
Action code Failure code Sens Supply 1 Volt High Error

Trouble
Contents of trouble • Signal voltage in sensor power supply (5 V) circuit is abnormally high.
Action of controller operation.
• Output drops.
on machine

Disconnect devices at Atmospheric
Defective sensor (Inter- PAMB connector
2 right in order. If error pressure sensor
nal trouble) code disappears when a
device is disconnected, Bypass valve lift
that device has a defect SBP connector
sensor
in it.
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
in wiring or defective (33) – each sensor (female) (5 V circuit)
contact in connector) Wiring harness between ENG (female)
(38) – each sensor (female) (ENG circuit)
mal state
without turning starting switch ON.
4 harness (Short circuit Resistance Min. 1 Mz
(33) – each sensor (female) (5 V circuit)
with GND circuit)
(38) – each sensor (female) (ENG circuit)
Short circuit in wiring
5 harness (with another Wiring harness between ENG (female)
wiring harness) (33) – each sensor (female) (5 V circuit)
and between ENG (female) (38) – each
sensor (female) (ENG circuit)
6
ler ENG Voltage
Between (33) – (38) 4.75 – 5.25 V
16 PC600-8
Circuit diagram related to sensor power supply 1 (5 V)
PC600-8 17
Failure code [CA441] Battery Voltage Low Error
Action code Failure code Battery Voltage Low Error

Trouble
Contents of trouble • Power supply voltage is abnormally low.
on machine start.
• Signal voltage of power supply voltage can be checked with monitoring function.
Related information
(Code: 03200 Power supply voltage)

Failure code [CA442] Battery Voltage High Error
Action code Failure code Battery Voltage High Error

Trouble
Contents of trouble • Power supply voltage is abnormally high.
on machine start.

18 PC600-8
Failure code [CA449] Rail Press Very High Error
Action code Failure code Rail Press Very High Error

Trouble
Contents of trouble • Common rail pressure sensor circuit detected abnormally high pressure (level 2).
• Output drops.
on machine
• Signal voltage of common rail pressure can be checked with monitoring function.
Related information
(Code: 36400 Common rail pressure)

PC600-8 19
Failure code [CA451] Rail Press Sensor High Error
Action code Failure code Rail Press Sensor High Error

Trouble
Contents of trouble • Signal voltage in common rail pressure sensor circuit is abnormally high.
• Output drops.
on machine
• Signal voltage of common rail pressure sensor can be checked with monitoring function.
Related information
(Code: 36401 Common rail pressure voltage)

1
supply shooting for it first.
PFUEL Voltage
Defective common rail
2 pressure sensor (Internal
trouble) Between (2) – (3) Signal 0.25 – 4.6 V
Resistance Max. 1 z
harness (Disconnection (37) – PFUEL (female) (1)
3
(25) – PFUEL (female) (2)
Resistance Max. 1 z
(47) – PFUEL (female) (3)
Possible causes and
standard value in nor- a Prepare with starting switch OFF, then carry out troubleshoot-
mal state ing without turning starting switch ON.
(37) – PFUEL (female) (1) and chassis Resistance Min. 1 Mz
Ground fault in wiring ground
4 harness (Short circuit Wiring harness between ENG (female)
with GND circuit) (25) – PFUEL (female) (2) and chassis Resistance Min. 1 Mz
ground
(47) – PFUEL (female) (3) and chassis Resistance Min. 1 Mz
ground
(37) – PFUEL (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (25) – PFUEL (female) (2)
harness) (37) – PFUEL (female) (1) and between Resistance Min. 1 Mz
ENG (female) (47) – PFUEL (female) (3)
(25) – PFUEL (female) (2) and between Resistance Min. 1 Mz
ENG (female) (47) – PFUEL (female) (3)
20 PC600-8

Possible causes and or start engine and carry out troubleshooting.
standard value in nor- Defective engine control-
6 ENG Voltage
mal state ler
Between (37) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
PC600-8 21
Failure code [CA452] Rail Press Sensor Low Error
Action code Failure code Rail Press Sensor Low Error

Trouble
Contents of trouble • Signal voltage in common rail pressure sensor circuit is abnormally low.
• Output drops.
on machine
• Signal voltage of common rail pressure sensor can be checked with monitoring function.
Related information
(Code: 36401 Common rail pressure voltage)

Failure code [CA553] Rail Press High Error
Action code Failure code Rail Press High Error

Trouble
Contents of trouble • Common rail pressure sensor circuit detected abnormally high pressure (level 1).
• Output drops.
on machine
• Signal voltage of common rail pressure can be checked with monitoring function.
Related information
(Code: 36400 Common rail pressure)

If another failure code is indicated, carry out troubleshooting for
it.
2 Use of improper fuel Check fuel used directly (for high viscosity).
Defective electrical system
Common rail pressure sensor may have electric trouble. Carry
3 of common rail pressure
Possible causes and out troubleshooting for code [CA451].
sensor
mal state Defective mechanical sys-
Check mechanical system of common rail pressure sensor
4 tem of common rail pres-
directly.
sure sensor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
22 PC600-8
Failure code [CA554] Rail Press Sensor In Range Error
Action code Failure code Rail Press Sensor In Range Error

Trouble
— CA554 (Engine controller system)
Contents of trouble • In-range error occurred in common rail pressure sensor circuit.
• Output drops.
on machine

PC600-8 23
Failure code [CA559] Rail Press Low Error
Action code Failure code Rail Press Low Error

Trouble
Contents of trouble • Supply pump does not feed fuel (level 1).
Action of controller • Limits common rail pressure.
• Output drops.
on machine

it.
2 Use of improper fuel Check fuel used directly (for high viscosity).
a For contents of troubleshooting, see Note 1. For check of
pressure in fuel low-pressure circuit, see TESTING AND
Defective low-pressure cir- ADJUSTING, Testing fuel pressure.
3
cuit device
Pressure in fuel low-pressure Min. 0.15 MPa
circuit {Min. 1.5 kg/cm2}
4 Clogging of filter/strainer a For contents of troubleshooting, see Note 2.
Supply pump PCV may have electric trouble. Carry out trouble-
Defective electrical system
5 shooting for following codes;
of supply pump PCV
[CA271], [CA272], [CA273], [CA274].
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring
Possible causes and 6
sure sensor harness for damage.
mal state a For testing of leakage from pressure limiter, see TESTING
7 Defective pressure limiter AND ADJUSTING, Testing leakage and return rate of fuel.
Leakage from pressure limiter Max. 10 cc/min (at 1,600 rpm)
a For testing of return (spill) limit from injector, see TESTING
AND ADJUSTING, Testing leakage and return rate of fuel.
Return (Spill) limit from
Speed at rated operation
injector
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
If causes 1 – 8 are not detected, supply pump may be defec-
9 Defective supply pump
tive.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-pres-
sure feed”.
24 PC600-8
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
• Overflow valve (1): Spring is seen through both holes.
• Bypass valve (2): Spring is seen through hole on nut side.
• 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.
PC600-8 25
Check sheet for no-pressure feed

Model Work No.
Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm 800 ± 25
*1 Engine speed High idle rpm 1,950 ± 50
Equivalent to rating rpm 1,800
Low idle % 0
*2 Throttle opening
High idle % 100
Fuel injection com-
*3 Equivalent to rating mm3 — — —
mand
Common rail pres- MPa
4 *4 Equivalent to rating
sure command {kg/cm2}
Common rail fuel MPa
*5 Equivalent to rating
pressure {kg/cm2}
Low idle CA — — —
Fuel injection tim-
*6 High idle CA — — —
ing command
Equivalent to rating CA — — —
kPa
*7 Boost pressure Equivalent to rating — — —
{kg/cm2}
Engine coolant tem-
*8 Low idle °C — — —
perature
*9 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Function Reduced cylinder Checking condition Unit Measured value Good NG
(Reference value)
No. 1 cylinder Low idle rpm — — —
5 No. 2 cylinder Low idle rpm — — —
*10
Standard value
C. Check of fuel circuit pressure Checking condition Unit Measured value Good NG
(Reference value)
Fuel low-pressure circuit pres- MPa Min. 0.15 MPa
6 High idle
sure {kg/cm2} {Min. 1.5 kg/cm2}
D. Check of strainers and filters Good NG

7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E. Check of leakage and Standard value

Checking condition Unit Measured value Good NG
return rate (Reference value)
Leakage through pressure lim-
11 No load, 1,600 rpm cc/min Max. 10
iter
Equivalent to rating 1,600 rpm cc/min 960 Speed:
Equivalent to rating 1,700 rpm cc/min 1,020
12 Return rate from injector Equivalent to rating 1,800 rpm cc/min 1,080
Equivalent to rating 1,900 rpm cc/min 1,140 Return rate:
Equivalent to rating 2,000 rpm cc/min 1,200
26 PC600-8
*1 – *10:
When inspecting with the monitoring function, see the monitoring codes list.
Equivalent to rating:
Relieve the oil under the following condition.
1) Run engine at full throttle.
2) Select P mode.
3) Raise boom.
PC600-8 27
Failure code [CA689] Eng Ne Speed Sensor Error
Action code Failure code Eng Ne Speed Sensor Error

Trouble
Contents of trouble • Abnormality occurred in engine Ne speed sensor circuit.
Action of controller • Operates with signals of Bkup speed sensor.
Problem that appears • Running engine stops (when Bkup speed sensor is also abnormal).
on machine • Stopped engine cannot be started (when Bkup speed sensor is also abnormal).

Defective sensor power If failure code [CA238] is indicated, carry out troubleshooting for
1
supply system it first.
Resistance Max. 1 z
harness (Disconnection (16) – NE (female) (1)
2
(48) – NE (female) (2)
Resistance Max. 1 z
(27) – NE (female) (3)
(16) – NE (female) (1) and chassis Resistance Min. 1 Mz
with GND circuit) (48) – NE (female) (2) and chassis Resistance Min. 1 Mz
Possible causes and ground
mal state
(27) – NE (female) (3) and chassis Resistance Min. 1 Mz
ground
(16) – NE (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (48) – NE (female) (2)
harness) (16) – NE (female) (1) and between Resistance Min. 1 Mz
ENG (female) (27) – NE (female) (3)
(48) – NE (female) (2) and between Resistance Min. 1 Mz
ENG (female) (27) – NE (female) (3)
If causes 1 – 4 are not detected, engine Ne speed sensor may
Defective engine Ne
5 be defective. (Since trouble is in system, troubleshooting cannot
speed sensor
be carried out.)
If causes 1 – 4 are not detected, engine controller may be defec-
Defective engine control-
6 tive. (Since trouble is in system, troubleshooting cannot be car-
ler
ried out.)
28 PC600-8
Circuit diagram related to engine Ne speed sensor
PC600-8 29
Failure code [CA691] Intake Air Temp Sens High Error

Action code Failure code Failure Intake Air Temp Sens High Error
E15 CA691 phenomenon (Engine controller system)
Failure content • High error occurred in intake air temperature sensor circuit.
Response from
• Fixes intake air temperature to 0°C and continues operation.
controller
Phenomenon
occurring on —
machine
Relative • Signal voltage of intake air temperature sensor can be checked with monitoring function.
information (Code: 18401 Intake air temperature sensor voltage)

starting switch ON.
Defective intake air tem- TINLT (male) Intake air temperature Resistance
1 perature sensor (Internal
defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A), (B) –
All range Min. 1 Mz
chassis ground
Presumed cause and
Disconnection in wiring starting switch ON.

harness (Disconnection Wiring harness between ENG (female) (43) – TINLT
in wiring or defective con- (female) (A)
tact in connector) Wiring harness between ENG (female) (47) – TINLT
Resistance Max. 1 z
(female) (B)
3 harness (Contact with
GND circuit) Wiring harness between ENG (female) (43) – TINLT
(female) (B) and chassis ground
starting switch ON.
4 Defective pump controller
ENG (female) Intake air temperature Resistance
Between (43) – (47) 10 – 100°C 0.5 – 20 kz
Circuit diagram related to intake air temp sensor
30 PC600-8
Failure code [CA692] Intake Air Temp Sens Low Error

Action code Failure code Failure Intake Air Temp Sens Low Error
Failure content • Low error occurred in intake air temperature sensor circuit.
Response from
• Fixes intake air temperature to 0°C and continues operation.
controller
Phenomenon
occurring on —
machine
Relative • Signal voltage of intake air temperature sensor can be checked with monitoring function.
information (Code: 18401 Intake air temperature sensor voltage)

Presumed cause and
Carry out troubleshooting for failure code [CA691].
PC600-8 31
Failure code [CA697] ECM Int Temp Sens High Error

Action code Failure code Failure ECM Int Temp Sens High Error
Failure content • High error occurred in temperature sensor circuit in engine controller.
Response from
controller
Phenomenon
occurring on —
machine
Relative
—
information

Presumed cause and
Defective engine
1 Controller may have defect in it (troubleshooting cannot be carried out).
controller
Failure code [CA698] ECM Int Temp Sens Low Error

Action code Failure code Failure ECM Int Temp Sens Low Error
Failure content • Low error occurred in temperature sensor circuit in engine controller.
Response from
controller
Phenomenon
occurring on —
machine
Relative
—
information

Presumed cause and
Defective engine
1 Controller may have defect in it (troubleshooting cannot be carried out).
controller
32 PC600-8
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Action code Failure code Eng Bkup Speed Sens Phase Error
Trouble
Contents of trouble • Engine Bkup sensor circuit detected abnormality in phase.
Action of controller • Controls with signals of engine Ne speed sensor.
Problem that appears • Running engine stops (when Ne speed sensor is also abnormal).
on machine • Stopped engine cannot be started (when Ne speed sensor is also abnormal).

Possible causes and Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble-
1
standard value in nor- sensor system shooting for failure code [CA698].
mal state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trou-
2
speed sensor system bleshooting for failure code [CA778].
Failure code [CA757] All Persistent Data Lost Error
Action code Failure code All Persistent Data Lost Error

Trouble
Contents of trouble • All data in engine controller are lost.
on machine start.

PC600-8 33
Failure code [CA778] Engine Bkup Speed Sensor Error
Action code Failure code Engine Bkup Speed Sensor Error

Trouble
Contents of trouble • Abnormality occurred in engine Bkup speed sensor circuit.
• Operates with signals of Ne speed sensor.
• Limits output and continues operation.
• Output drops.
• Running engine stops (when Ne speed sensor is also abnormal).
on machine
• Stopped engine cannot be started (when Ne speed sensor is also abnormal).

1
Resistance Max. 1 z
harness (Disconnection (37) – G (female) (1)
2
(47) – G (female) (2)
Resistance Max. 1 z
(26) – G (female) (3)
(37) – G (female) (1) and chassis Resistance Min. 1 Mz
with GND circuit) (47) – G (female) (2) and chassis Resistance Min. 1 Mz
Possible causes and ground
mal state
(26) – G (female) (3) and chassis Resistance Min. 1 Mz
ground
(37) – G (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring har- (female) (47) – G (female) (2)
harness) (37) – G (female) (1) and between ENG Resistance Min. 1 Mz
(female) (26) – G (female) (3)
(47) – G (female) (2) and between ENG Resistance Min. 1 Mz
(female) (26) – G (female) (3)
If causes 1 – 4 are not detected, engine Bkup speed sensor may
Defective engine Bkup
5 be defective. (Since trouble is in system, troubleshooting cannot
speed sensor
be carried out.)
If causes 1 – 5 are not detected, engine controller may be defec-
6 tive. (Since trouble is in system, troubleshooting cannot be car-
ler
ried out.)
34 PC600-8
Circuit diagram related to engine Bkup speed sensor
PC600-8 35
Failure code [CA1117] Persistent Data Lost Error
Action code Failure code Persistent Data Lost Error

Trouble
Contents of trouble • Persistent data lost error occurred in engine controller.
—
on machine

Failure code [CA1228] EGR Valve Servo Error 1
Action code Failure code EGR Valve Servo Error 1

Trouble
Contents of trouble • Abnormality (level 1) occurred in EGR valve servo.
Action of controller • Performs open control.
—
on machine

it.
a For check of engine oil pressure, see TESTING AND
ADJUSTING, Testing engine oil pressure.
Engine Engine oil pressure
Defective engine oil pres-
2 Low idle 0.08 MPa {0.8 kg/cm2}
sure system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2}
Possible causes and If engine oil pressure is abnormal, carry out troubleshooting of
standard value in nor- engine (S-12 Oil pressure lowers).
mal state Defective oil pump for EGR
3 Check oil pump and relief valve for EGR valve circuit directly.
valve
Defective oil feed piping for
4 Check oil feed piping for EGR valve circuit directly.
EGR valve
Defective oil return piping
5 Check oil return piping for EGR valve circuit directly.
for EGR valve
6 Defective EGR valve Check mechanical section of EGR valve directly.
be carried out.)
36 PC600-8
Failure code [CA1625] EGR Valve Servo Error 2
Action code Failure code EGR Valve Servo Error 2

Trouble
Contents of trouble • Abnormality (level 2) occurred in EGR valve servo.
• Closes EGR valve and bypass valve.
• Output drops.
on machine

PC600-8 37
Failure code [CA1626] BP Valve Sol Current High Error
Action code Failure code BP Valve Sol Current High Error

Trouble
Contents of trouble • There is short circuit in drive circuit of bypass valve solenoid.
• Output drops.
on machine

Defective bypass valve ing without turning starting switch ON.
1
solenoid (Internal trouble) BP (male) Resistance
Between (1) – (2) 10 – 21 z
in wiring or defective con- (31) – BP (female) (1)
Resistance Max. 1 z
(11) – BP (female) (2)
Possible causes and Ground fault in wiring
(31) – BP (female) (1) and chassis Resistance Min. 1 Mz
standard value in nor- 3 harness (Short circuit
ground
mal state with GND circuit)
(11) – BP (female) (2) and chassis Resistance Min. 1 Mz
ground
(31) – BP (female) (1) and chassis Voltage Max. 1 V
4 with 24V circuit) in wiring
ground
harness
(11) – BP (female) (2) and chassis Voltage Max. 1 V
ground
Defective engine control- ing without turning starting switch ON.
5
ler ENG (female) Resistance
Between (31) – (11) 10 – 21 z
38 PC600-8
Circuit diagram related to bypass valve solenoid & lift sensor
PC600-8 39
Failure code [CA1627] BP Valve Sol Current Low Error
Action code Failure code BP Valve Sol Current Low Error

Trouble
Contents of trouble • There is disconnection in drive circuit of bypass valve solenoid.
• Output drops.
on machine

Failure code [CA1628] Bypass Valve Servo Error 1
Action code Failure code Bypass Valve Servo Error 1

Trouble
Contents of trouble • Abnormality (level 1) occurred in bypass valve servo.
Action of controller • Performs open control.
—
on machine

If another failure code is indicated, carry out troubleshooting
for it.
a For check of engine oil pressure, see TESTING AND
ADJUSTING, Testing engine oil pressure.
Engine Engine oil pressure
Defective engine oil pres-
2 Low idle 0.08 MPa {0.8 kg/cm2}
sure system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2}
Possible causes and If engine oil pressure is abnormal, carry out troubleshooting
standard value in nor- for mechanical system (S-12 Oil pressure lowers).
mal state Defective oil pump for Check oil pump and relief valve for bypass valve circuit
3
bypass valve directly.
Defective oil feed piping for
4 Check oil feed piping for bypass valve circuit directly.
bypass valve
Defective oil return piping
5 Check oil return piping for bypass valve circuit directly.
for bypass valve
6 Defective bypass valve Check mechanical section of bypass valve directly.
be carried out.)
40 PC600-8
Failure code [CA1629] Bypass Valve Servo Error 2
Action code Failure code Bypass Valve Servo Error 2

Trouble
Contents of trouble • Abnormality (level 2) occurred in bypass valve servo.
• Output drops.
on machine

PC600-8 41
Failure code [CA1631] BP Valve Pos Sens High Error
Action code Failure code BP Valve Pos Sens High Error

Trouble
Contents of trouble • Signal voltage in bypass valve lift sensor circuit is abnormally high.
• Output drops.
on machine
• Signal voltage of bypass valve position sensor can be checked with monitoring function.
Related information
(Code: 18200 Bypass valve position sensor voltage)

1
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective bypass valve SBP Voltage
2 lift sensor (Internal trou- Between (1) – (2) Power supply 4.75 – 5.25 V
ble)
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
Resistance Max. 1 z
harness (Disconnection (33) – SBP (female) (1)
3
in wiring or defective Wiring harness between ENG (female)
contact in connector) Resistance Max. 1 z
(38) – SBP (female) (2)
Resistance Max. 1 z
(29) – SBP (female) (3), (4)
Possible causes and without turning starting switch ON.
(33) – SBP (female) (1)
(38) – SBP (female) (2)
(29) – SBP (female) (3), (4)
(33) – SBP (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring (female) (38) – SBP (female) (2)
5 harness (with another Wiring harness between ENG (female)
wiring harness) (33) – SBP (female) (1) and between ENG Resistance Min. 1 Mz
(female) (29) – SBP (female) (3), (4)
(38) – SBP (female) (2) and between ENG Resistance Min. 1 Mz
(female) (29) – SBP (female) (3), (4)
Defective engine con- start engine and carry out troubleshooting.
6
troller ENG Voltage
Between (33) – (38) 4.75 – 5.25 V
42 PC600-8
Circuit diagram related to bypass valve solenoid & lift sensor
PC600-8 43
Failure code [CA1632] BP Valve Pos Sens Low Error
Action code Failure code BP Valve Pos Sens Low Error

Trouble
Contents of trouble • Signal voltage in bypass valve lift sensor circuit is abnormally low.
• Output drops.
on machine
• Signal voltage of bypass valve lift sensor can be checked with monitoring function.
Related information
(Code: 18200 Bypass valve lift sensor voltage)

44 PC600-8
PC600-8 45
Failure code [CA1633] KOMNET Datalink Timeout Error

Action code Failure Code Failure KOMNET Datalink Timeout Error
E0E CA1633 phenomenon (Engine controller system)
Failure content • Abnormality occurred in circuit of KOMNET communication with machine monitor.
Response from
• Operates in default mode or maintains condition when abnormality occurs.
monitor panel
Phenomenon
occurring on —
machine
Relative
—
information

Disconnection of wiring
Wiring harness between CM03 (female) (16) and CE02
harness Resistance
(female) (47) or between CM03 (female) (16) and CP02 Max. 1 z
1 (Disconnection or defec- value
(female) (22)
tor) Wiring harness between CM03 (female) (15) and CE02
Resistance
value
(female) (32)
Between wiring harness between CM03 (female) (16)
Grounding fault of wiring and CE02 (female) (47) or between CM03 (female) (16) Resistance
Min. 1 Mz
harness and CP02 (female) (22) or between CM03 (female) (16) value
2
(Contact with grounding and related circuits and grounding

Presumed cause and
circuit) Between wiring harness between CM03 (female) (15)

and CE02 (female) (46) or between CM03 (female) (15) Resistance
Min. 1 Mz
and CP02 (female) (32) or between CM03 (female) (15) value
and related circuits and grounding
and CE02 (female) (47) or between CM03 (female) (16)
Short-circuiting of wiring Voltage Max. 1 V
and CP02 (female) (22) or between CM03 (female) (16)
3 harness
(Contact with 24 V circuit)
Voltage Max. 1 V
CAN terminal resistor position during the troubleshooting.
4
defective K02 (male), K03 (male) Voltage
Between (1) and (2) 40 – 80 z
Machine monitor, engine If causes 1 – 4 are not detected, machine monitor, engine controller, or pump control-
5 controller, or pump ler may be defective. (Since trouble is in those devices, troubleshooting cannot be
controller defective carried out.)
46 PC600-8
Electrical circuit diagram related to CAN communication
PC600-8 47
Failure code [CA1642] EGR Inlet Press Sens Low Error
Action code Failure code EGR Inlet Press Sens Low Error
Trouble
Contents of trouble • Signal voltage in EGR inlet pressure sensor circuit is abnormally low.
• Sets EGR inlet pressure to default value (102 kPa {1.0 kg/cm2}) and continues operation.
• Output drops.
on machine
• Signal voltage of EGR inlet pressure sensor can be checked with monitoring function.
Related information
(Code: 18001 EGR inlet sensor voltage)

48 PC600-8
PC600-8 49
Failure code [CA1653] EGR Inlet Press Sens High Error
Action code Failure code EGR Inlet Press Sens High Error
Trouble
Contents of trouble • Signal voltage in EGR inlet pressure sensor circuit is abnormally high.
• Sets EGR inlet pressure to default value (102 kPa {1.0 kg/cm2}) and continues operation.
• Output drops.
on machine
• Signal voltage of EGR inlet pressure sensor can be checked with monitoring function.
Related information
(Code: 18001 EGR inlet pressure sensor voltage)

1
Defective EGR inlet pres- PEVA Voltage
2 sure sensor (Internal Between (1) – (2) Power supply 4.75 – 5.25 V
trouble)
Resistance Max. 1 z
harness (Disconnection (37) – PEVA (female) (1)
3
tact in connector) Resistance Max. 1z
(47) – PEVA (female) (2)
Resistance Max. 1 z
(20) – PEVA (female) (3)
standard value in nor- Wiring harness between ENG (female) (37)
– PEVA (female) (1) and chassis ground
with GND circuit) Wiring harness between ENG (female) (47)
Wiring harness between ENG (female) (20)
(37) – PEVA (female) (1) and between Resistance Min. 1 Mz
Short circuit in wiring har- ENG (female) (47) – PEVA (female) (2)
harness) (37) – PEVA (female) (1) and between Resistance Min. 1 Mz
ENG (female) (20) – PEVA (female) (3)
(47) – PEVA (female) (2) and between Resistance Min. 1 Mz
ENG (female) (20) – PEVA (female) (3)
6
ler ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
50 PC600-8
Circuit diagram related to EGR inlet pressure sensor
PC600-8 51
Failure code [CA2185] Throt Sens Sup Volt High Error
Action code Failure code Throt Sens Sup Volt High Error
Trouble
Contents of trouble • Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
• Sets throttle angle with signal other than throttle sensor signal and continues operation
(depending on each model).
• Depends on machine model.
on machine

Defective accelerator Disconnect devices at right

1 in order. If error code dis-
pedal (Internal trouble) Fuel dial
appears when a device is P20 connector
control
disconnected, that device
has a defect in it.
Disconnection in wiring without turning starting switch ON.
harness (Disconnection Wiring harness between CE02 (female)
in wiring or defective (22) – P20 (female) (1)
contact in connector) Wiring harness between CE02 (female)
Resistance Max. 1 z
(23) – P20 (female) (3)
Possible causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value in nor- without turning starting switch ON.
mal state Wiring harness between CE02 (female)
(22) – P20 (female) (1) and chassis Resistance Min. 1 Mz
ground
with GND circuit)
Wiring harness between CE02 (female)
(23) – P20 (female) (3) and chassis Resistance Min. 1 Mz
ground
Short circuit in wiring without turning starting switch ON.
4 harness (with another Wiring harness between CE02 (female)
wiring harness) (22) – P20 (female) (1) and between Resistance Min. 1 Mz
CE02 (female) (23) – P20 (female) (3)
Defective engine con- and carry out troubleshooting.
5
troller CE02 Voltage
Between (22) – (23) 4.75 – 5.25 V
52 PC600-8
Circuit diagram related to throttle sensor of fuel control dial type
PC600-8 53
Failure code [CA2186] Throt Sens Sup Volt Low Error
Action code Failure code Throt Sens Sup Volt Low Error
Trouble
Contents of trouble • Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low.
Action of controller • Sets throttle angle with signal other than throttle sensor signal and continues operation.
—
on machine

Failure code [CA2249] Rail Press Very Low Error
Action code Failure code Rail Press Very Low Error

Trouble
Contents of trouble • Supply pump does not feed fuel (level 2).
Action of controller • Limits common rail pressure.
• Output drops.
on machine

54 PC600-8
PC600-8 55
Failure code [CA2271] EGR Valve Pos Sens High Error
Action code Failure code EGR Valve Pos Sens High Error
Trouble
Contents of trouble • Signal voltage in EGR valve lift sensor circuit is abnormally high.
• Output drops.
on machine
• Signal voltage of EGR valve lift sensor can be checked with monitoring function.
Related information
(Code: 18101 EGR valve lift sensor voltage)

Defective sensor If failure code [CA187] or [CA227] is indicated, carry out trouble-
1
power supply shooting for it first.
start engine and carry out troubleshooting.
Defective EGR valve SEGR Voltage
2 lift sensor (Internal Between (1) – (2) Power supply 4.75 – 5.25V
trouble)
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
Disconnection in wiring Wiring harness between ENG (female) (37)
harness (Disconnec- Resistance Max. 1 z
– SEGR (female) (1)
3 tion in wiring or defec-
tive contact in Wiring harness between ENG (female) (47)
Resistance Max. 1 z
connector) – SEGR (female) (2)
Resistance Max. 1 z
– SEGR (female) (3), (4)
Possible causes and
standard value in nor- Wiring harness between ENG (female) (37)
mal state Ground fault in wiring – SEGR (female) (1) and chassis ground
4 harness (Short circuit Wiring harness between ENG (female) (47)
with GND circuit) Resistance Min. 1 Mz
– SEGR (female) (2) and chassis ground
– SEGR (female) (3), (4) and chassis Resistance Min. 1 Mz
ground
– SEGR (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring (female) (47) – SEGR (female) (2)
5 harness (with another Wiring harness between ENG (female) (37)
wiring harness) – SEGR (female) (1) and between ENG Resistance Min. 1 Mz
(female) (19) – SEGR (female) (3), (4)
– SEGR (female) (2) and between ENG Resistance Min. 1 Mz
(female) (19) – SEGR (female) (3), (4)
Defective engine con- start engine and carry out troubleshooting.
6
troller ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
56 PC600-8
Circuit diagram related to EGR valve solenoid & lift sensor
PC600-8 57
Failure code [CA2272] EGR Valve Pos Sens Low Error
Action code Failure code EGR Valve Pos Sens Low Error
Trouble
Contents of trouble • Signal voltage in EGR valve lift sensor circuit is abnormally low.
• Output drops.
on machine
• Signal voltage of EGR valve lift sensor can be checked with monitoring function.
Related information
(Code: 18101 EGR valve lift sensor voltage)

58 PC600-8
PC600-8 59
Failure code [CA2351] EGR Valve Sol Current High Error
Action code Failure code EGR Valve Sol Current High Error
Trouble
Contents of trouble • There is short circuit in drive circuit of EGR valve solenoid.
• Output drops.
on machine

Defective EGR valve ing without turning starting switch ON.
1
solenoid (Internal trouble) EGR (male) Resistance
Between (1) – (2) 10 – 21 z
in wiring or defective con- (22) – EGR (female) (1)
Resistance Max. 1 z
(11) – EGR (female) (2)
Possible causes and Ground fault in wiring
(22) – EGR (female) (1) and chassis Resistance Min. 1 Mz
standard value in nor- 3 harness (Short circuit
ground
mal state with GND circuit)
(11) – EGR (female) (2) and chassis Resistance Min. 1 Mz
ground
(22) – EGR (female) (1) and chassis Voltage Max. 1 V
ground
harness
(11) – EGR (female) (2) and chassis Voltage Max. 1 V
ground
Defective engine control- ing without turning starting switch ON.
5
ler ENG (female) Resistance
Between (22) – (11) 10 – 21 z
60 PC600-8
Circuit diagram related to EGR valve solenoid & lift sensor
PC600-8 61
Failure code [CA2352] EGR Valve Sol Current Low Error
Action code Failure code EGR Valve Sol Current Low Error
Trouble
Contents of trouble • There is disconnection in drive current of EGR valve solenoid.
• Output drops.
on machine

mal state Carry out troubleshooting failure code [CA2351].
Failure code [CA2555] Grid Htr Relay Volt Low Error
Action code Failure code Grid Htr Relay Volt Low Error
Trouble
Contents of trouble • There is low voltage error in intake air heater relay circuit.
• Engine does not start easily at low temperature.
on machine

mal state Carry out troubleshooting failure code [CA2556].
62 PC600-8
PC600-8 63
Failure code [CA2556] Grid Htr Relay Volt High Error
Action code Failure code Grid Htr Relay Volt High Error
Trouble
Contents of trouble • There is high voltage error in intake air heater relay circuit.
• Engine does not start easily at low temperature.
on machine

Defective intake air ing without turning starting switch ON.
1 heater relay (Internal
R18 (male) Resistance
trouble)
Between (1) – (2) 200 – 400 z
harness (Disconnection Wiring harness between CE02 (female)
in wiring or defective con- (40) – R18 (female) (1)
tact in connector) Wiring harness between CE02 (female)
Resistance Max. 1 z
(42) – R18 (female) (2)
Possible causes and a Prepare with starting switch OFF, then carry out troubleshoot-
standard value in nor- ing without turning starting switch ON.
mal state Wiring harness between CE02 (female)
(40) – R18 (female) (1) and chassis Resistance Min. 1 Mz
ground
with GND circuit)
Wiring harness between CE02 (female)
(42) – R18 (female) (2) and chassis Resistance Min. 1 Mz
ground
CE02 Heater relay Voltage
4 Under operating
ler Max. 1 V
condition
Between (40) – (42)
Under stopping
20 – 30 V
condition
64 PC600-8
Circuit diagram related to intake air heater
PC600-8 65
©2006 KOMATSU
All Rights Reserved
66
UEN00450-00
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 K50001 and up

40 Troubleshooting

Failure code [D110KB] Battery Relay Drive S/C............................................................................................. 4
Failure code [D163KB] Flash Light Relay S/C................................................................................................ 6
Failure code [D195KB] Step Light Relay S/C ................................................................................................. 8
Failure code [DA25KP] Press. Sensor Power Abnormality .......................................................................... 10
Failure code [DA2SKQ] Model Selection Abnormality.................................................................................. 12
Failure code [DA80MA] Auto. Lub Abnormal................................................................................................ 14
Failure code [DA2RMC] Pump Comm. Abnormality..................................................................................... 16
Failure code [DAFRMC] Monitor Comm. Abnormality .................................................................................. 18
Failure code [DGE5KY] Ambi. Temp. Sensor S/C ........................................................................................ 20
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C ................................................................................... 21
Failure code [DHPAMA] F pump P. Sensor Abnormality .............................................................................. 22
Failure code [DHPBMA] R pump P. Sensor Abnormality.............................................................................. 24
Failure code [DV20KB] Travel Alarm S/C..................................................................................................... 26
Failure code [DW43KA] Travel Speed Sol. Disc........................................................................................... 28
Failure code [DW43KB] Travel Speed Sol. S/C............................................................................................ 30
Failure code [DW45KA] Swing Brake Sol. Disc............................................................................................ 32
Failure code [DW45KB] Swing Brake Sol. S/C............................................................................................. 34
Failure code [DW48KA] CO Cancel Sol. Disc. ............................................................................................. 36
Failure code [DW48KB] CO Cancel Sol. S/C ............................................................................................... 38
PC600-8 1
Failure code [DW7BKA] Fan Reverse Sol. Disc. .......................................................................................... 40

Failure code [DW7BKB] Fan Reverse Sol. S/C ............................................................................................ 41
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc. ........................................................................... 42
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C ............................................................................. 44
Failure code [DWK0KA] 2-stage Relief Sol. Disc. ........................................................................................ 46
Failure code [DWK0KB] 2-stage Relief Sol. S/C .......................................................................................... 48
Failure code [DX16KA] Fan Pump EPC Sol. Disc. ....................................................................................... 50
Failure code [DX16KB] Fan Pump EPC Sol. S/C ......................................................................................... 52
Failure code [DXA0KA] TVC Sol. Disc. ........................................................................................................ 54
Failure code [DXA0KB] TVC Sol. S/C .......................................................................................................... 56
Failure code [DY20KA] Wiper Working Abnormality..................................................................................... 58
Failure code [DY20MA] Wiper Parking Abnormality ..................................................................................... 60
Failure code [DY2CKB] Washer Drive S/C ................................................................................................... 64
Failure code [DY2DKB] Wiper Drive (For) S/C ............................................................................................. 66
Failure code [DY2EKB] Wiper Drive (Rev) S/C ............................................................................................ 70
2 PC600-8
PC600-8 3

Part 3
Failure code [D110KB] Battery Relay Drive S/C
Action code Failure code Failure Battery Relay Drive S/C

— D110KB phenomenon (Pump controller system)
Failure content • When a signal is output to the battery relay drive circuit, abnormal current flowed.
Response from • The controller turns OFF the output to the battery relay drive circuit.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • There may be a trouble in writing data into the ROM (non-volatile memory) of each controller.
machine
Relative • Operation of the battery relay (ON or OFF) can be checked in the monitoring function.
information (Code No. 03700: Controller output 1)

Battery relay defective
1 (Internal short-circuiting Battery relay (Unit) Resistance value
or grounding fault) Between BR and E Approx. 100 z
Presumed cause and
Between BR and grounding Min. 1 Mz

Grounding fault of wiring position during the troubleshooting.
harness Between wiring harness between CP03 (female) (4),
2
(Contact with grounding D01, J01, battery relay terminal BR or between CP03 Resistance
circuit) Min. 1 Mz
(female) (4) and starting switch terminal BR or between value
CP03 (female) (4) and D01 (female) (2) and grounding
Pump controller
3 CP03 (female) Starting switch Voltage
defective
20 – 30 V
Between (4) and grounding ON o OFF
(For 0.5 sec)
a S/C: Short circuit
4 PC600-8
Electrical circuit diagram related to battery relay drive
PC600-8 5
Failure code [D163KB] Flash Light Relay S/C

Action code Failure code Failure Flash Light Relay S/C
• Abnormal current flowed in the flash light relay circuit (the primary circuit of the relay), when power is
Failure content
supplied to the circuit.
• The controller turns OFF the output to the coil circuit of the flash light relay.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The flash light does not flash.
machine
• Operation of the flash light relay circuit (the primary side of the relay) (ON or OFF) can be checked in
Relative the monitoring function. (Code No. 03701: Controller output 2)
information • This error code detects abnormality on the primary (coil) side of the flash light relay and cannot detect
abnormality on the secondary (contact) side.

Flash light relay defective position during the troubleshooting.
1
(Internal short-circuiting) R10 (male) Resistance value
Between (1) and (2) 250 – 350 z

Presumed cause and
2
(Contact with grounding Between wiring harness between CP03 (female) (18) Resistance
circuit) Min. 1 Mz
and R10 (female) (1) and grounding valve
CP03 Horn switch Voltage
Pump controller
3 20 – 30 V Max. 1 V
defective
Between (18) and ON (at constant cycle,
grounding 5 seconds)
OFF Max. 1 V
6 PC600-8
Electrical circuit diagram related to horn and flash light
PC600-8 7
Failure code [D195KB] Step Light Relay S/C

Action code Failure code Failure Step Light Relay S/C
• Abnormal current flowed in the step light relay circuit (the primary circuit of the relay), when power is
Failure content
supplied to the circuit.
• Power to the step light relay circuit is switched OFF.
Response from
controller
Phenomenon
occurring on • Step light does not light up.
machine
• Operation of the step light relay circuit (the primary side of the relay) (ON or OFF) can be checked in
Relative the monitoring function. (Code No. 03701: Controller output 2)
information • This error code detects abnormality on the primary (coil) side of the step light relay and cannot detect
abnormality on the secondary (contact) side.

Step light relay defective position during the troubleshooting.
1
(Internal short-circuiting) R09 (male) Resistance value
Between (2) and (1) 250 – 350 z

Presumed cause and
2
circuit) Min. 1 Mz
and R09 (female) (2) and grounding value
CP02 Step light switch Voltage
3 Pump controller defective
20 – 30 V
Between (19) and ON
(Kept for 60 sec)
grounding
OFF Max. 1 V
8 PC600-8
Electrical circuit diagram related to step light
PC600-8 9
Failure code [DA25KP] Press. Sensor Power Abnormality

Action code Failure code Failure Press. Sensor Power Abnormality
— DA25KP phenomenon (Pump controller system)
Failure content • Abnormal current flowed in the pressure sensor power supply (5 V) circuit.
Response from • Power to the power supply (5 V) circuit is switched OFF.
Phenomenon
• The pressure sensor signal is not input normally.
occurring on
• The error code of abnormality in the pressure sensor is displayed, too.
machine
Relative
—
information

a Disconnect the connector when the engine starting switch is in OFF, and hold it in
the ON position during the troubleshooting.
Pressure sensor Disconnect the parts Front pump

Connector P25
1 defective shown at right in order. pressure sensor
(Internal short-circuiting) If the error code goes off
when one of those parts is Rear pump
disconnected, that part is Connector P26

pressure sensor
Presumed cause and
defective.
Grounding fault of wiring Between wiring harness between CP01 (female) (22),
Resistance
harness A06, and P25 (female) (B) and grounding Min. 1 Mz
2 value
(Contact with grounding [Front pump pressure sensor system]
circuit) Between wiring harness between CP01 (female) (22),
Resistance
A06, and P26 (female) (B) and grounding Min. 1 Mz
value
[Rear pump pressure sensor system]
CP01 Voltage
Between (22) and (10) 4.5 – 5.5 V
10 PC600-8
Electrical circuit diagram related to pressure sensor power supply
PC600-8 11
Failure code [DA2SKQ] Model Selection Abnormality

Action code Failure code Failure Model Selection Abnormality
— DA2SKQ phenomenon (Pump controller system)
Failure content • A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC600).
Response from
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • None in particular with PC600 model
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
Relative function. (Code No. 00200: Controller Model Code)
information a Input of model selecting signals (ON or OFF) can be confirmed in the monitoring function.
(Code No. 02201: Switch Input 2)

Model selection connec- position during the troubleshooting.
tor defective S30 (male) Resistance value
1
(Internal disconnection or
short-circuiting) Between (2) , (3), (4) and (8) Min. 1 Mz
Between (1) and (8) Max. 1 z
harness
Wiring harness between CP02 (female) (37) and S30 Resistance

(male) (1) value
Presumed cause and

tor) Between wiring harness between S30 (male) (8) to J05 , Resistance
Max. 1 z
A07, J14, J15 and grounding value
Grounding fault of wiring Between wiring harness between CP02 (female) (27) Resistance
Min. 1 Mz
harness and S30 (male) (2) and grounding value
3
circuit) Min. 1 Mz
and S30 (male) (3) and grounding value
Between wiring harness between CP02 (female) (7) and Resistance
Min. 1 Mz
S30 (male) (4) and grounding value
4 Pump controller defective CP02 Voltage
Between (7), (17), (27) and grounding 20 – 30 V
Between (37) and grounding Max. 1 V
12 PC600-8
Electrical circuit diagram related to model selection connector (for pump controller)
PC600-8 13
Failure code [DA80MA] Auto. Lub Abnormal
a This failure code is applicable only when the auto grease device is installed.
14 PC600-8
PC600-8 15
Failure code [DA2RMC] Pump Comm. Abnormality

Action code Failure code Failure Pump Comm. Abnormality
E0E DA2RMC phenomenon (Pump controller system)
• The pump controller detected communication failure in the CAN communication circuit to the machine
Failure content
monitor or engine controller.
Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
Phenomenon
• The output lowers (The pump absorption torque is reduced).
occurring on
• If the working load increases, the engine may stall.
machine
Relative
—
information

harness Resistance
(female) (22)
Resistance
value
(female) (32)
Min. 1 Mz
2

Presumed cause and

Min. 1 Mz
3 harness
Voltage Max. 1 V
4
defective K02 (male), K03 (male) Resistance value
Between (A) and (B) 40 – 80 z
Monitor panel, If causes 1 – 4 are not detected, machine monitor, engine controller, or pump control-
5 engine controller, or ler may be defective. (Since trouble is in those devices, troubleshooting cannot be
pump controller defective carried out.)
16 PC600-8
PC600-8 17
Failure code [DAFRMC] Monitor Comm. Abnormality

Action code Failure code Failure Monitor Comm. Abnormality
E0E DAFRMC phenomenon (Machine monitor system)
• The machine monitor detected communication failure in the CAN communication circuit to the engine
Failure content
controller or pump controller.
Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
machine monitor • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The output lowers (The pump absorption torque is reduced).
occurring on
• If the working load increases, the engine may stall.
machine
Relative
—
information

harness Resistance
(female) (22)
Resistance
value
(female) (32)
Min. 1 Mz
2

Presumed cause and

Min. 1 Mz
3 harness
Voltage Max. 1 V
4
defective K02 (male), K03 (male) Voltage
Between (A) and (B) 40 – 80 z
Machine monitor, engine If causes 1 – 4 are not detected, machine monitor, engine controller, or pump control-
5 controller, or pump ler may be defective. (Since trouble is in those devices, troubleshooting cannot be
controller defective carried out.)
18 PC600-8
PC600-8 19
Failure code [DGE5KY] Ambi. Temp. Sensor S/C

Action code Failure code Failure Ambi. Temp. Sensor S/C
— DGE5KY phenomenon (Pump controller system)
Failure content • Abnormal current flowed in ambient temperature sensor circuit.
Response from • None in particular.
Phenomenon
occurring on • Fan rotation speed rises.
machine
Relative
—
information

Defective ambient starting switch ON.
1
temperature sensor P29 (male) Ambient temperature Resistance
Between (1) – (2) 20°C 4 – 6 kz
starting switch ON.

Presumed cause and
Disconnection in wiring
harness (Disconnection Wiring harness between CP01 (female) (9) – P29
in wiring or defective con- (female) (1)
tact in connector) Wiring harness between CP01 (female) (10) – P29
Resistance Max. 1 z
(female) (2)
Hot short (Short circuit troubleshooting.
3 with 24 V circuit) in wiring
harness Wiring harness between CP01 (female) (9) – P29
Voltage Max. 1 V
(female) (1)
starting switch ON.
P29 (male) Ambient temperature Resistance
Between (1) – (2) 20°C 4 – 6 kz
Circuit diagram related to ambient temperature sensor
20 PC600-8
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C

Action code Failure code Failure Hydr. Oil Temp. Sensor S/C
— DGH2KB phenomenon (Pump controller system)
Failure content • While engine was running, signal of hydraulic oil temperature sensor rose above 102°C.
Response from
machine monitor
Phenomenon
occurring on • If machine is operated as it is, hydraulic components may be damaged.
machine
• If hydraulic oil temperature monitor of monitor panel lights up red while engine is running, this failure
Relative code is recorded.
information • Input (temperature) from hydraulic oil temperature sensor can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature, 04402: Hydraulic oil temperature sensor voltage)

Overheating of hydraulic
Hydraulic oil may have been overheated. Remove cause and repair damaged
1 oil (When system is nor-
hydraulic parts.
mal)
starting switch ON.
Defective hydraulic oil P22 (male) Hydraulic oil temperature Resistance
2 temperature sensor
Presumed cause and
(Internal defect) Between (1) – (2) 90 – 3.5 kz

Between (1) – 10 – 100°C
Min. 1 Mz
chassis ground
GND circuit) Wiring harness between CM02 (female) (12) – P22
(female) (1) and chassis ground
starting switch ON.
Defective machine moni- CM02 (female) Hydraulic oil temperature Resistance
4
tor Between (12) – (13) 90 – 3.5 kz
Between (12) – 10 – 100°C
Min. 1 Mz
chassis ground
Electric circuit diagram related to hydraulic oil temperature sensor
PC600-8 21
Failure code [DHPAMA] F pump P. Sensor Abnormality

Action code Failure code Failure F pump P. Sensor Abnormality
— DHPAMA phenomenon (Pump controller system)
Failure content • Signal voltage from the front pump pressure sensor is Max. 0.3 V or Min. 4.42 V.
Response from
• When the failure cause disappears of itself, the machine operation returns to normalcy.
controller
Phenomenon
occurring on • The travel speed does not shift automatically (The travel load pressure cannot be detected).
machine
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure
Relative sensor will be broken. Accordingly, take extreme care when checking.
information • Input from the front pump pressure sensor (pressure) can be checked in the monitoring function. (Code
No. 01100: Front pump pressure)

Sensor power supply
1 If failure code [DA25KP] is displayed, carry out troubleshooting for it first.
system defective
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
P25 Voltage
Front pump pressure
Between (B) and (A) Power supply 4.5 – 5.5 V
2 sensor defective
(Internal defect) Between (C) and (A) Signal 0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,
for another cause of the trouble, and then judge.
Disconnection of wiring Wiring harness between CP01 (female) (22), A06, J25, Resistance
harness Max. 1 z
Presumed cause and
and P25 (female) (B) value

tive contact with connec- Wiring harness between CP01 (female) (10), A06, and Resistance
Max. 1 z
tor) P25 (female) (A) value
Wiring harness between CP01 (female) (8) and P25 Resistance
Max. 1 z
(female) (C) value
4
(Contact with grounding Between wiring harness between CP01 (female) (8) and Resistance
circuit) Min. 1 Mz
P25 (female) (C) and grounding value
Hot short
Between wiring harness between CP01 (female) (22),
5 (Short circuit with 24 V Voltage Max. 1 V
A06, J25, and P25 (female) (B) and grounding
circuit) in wiring harness
Between wiring harness between C01 (female) (8) and
Voltage Max. 1 V
P25 (female) (C) and grounding
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
Between (22) and (10) 4.5 – 5.5 V
Between (8) and (10) 0.5 – 4.5 V
22 PC600-8
Electrical circuit diagram related to front pump pressure sensor
PC600-8 23
Failure code [DHPBMA] R pump P. Sensor Abnormality

Action code Failure code Failure R pump P. Sensor Abnormality
— DHPBMA phenomenon (Pump controller system)
Failure content • Signal voltage from R pump pressure sensor is below 0.3 V or above 4.42 V.
Response from
• If cause of failure disappears, system resets itself.
controller
Phenomenon
occurring on • Transmission gear is not shifted automatically (Travel load pressure cannot be detected).
machine
a If 5 V circuit (B) and grounding (GND) circuit (A) of pressure sensor are connected inversely, pressure
Relative sensor will be broken. Take extreme care when checking.
information • Input (pressure) from R pump pressure sensor can be checked with monitoring function.
(Code: 01101 R pump pressure)

Defective sensor power
1 If failure code [DA25KP] is displayed, perform troubleshooting for it first.
supply system
a Prepare with starting switch OFF, then turn starting switch ON and start engine and
carry out troubleshooting in each case.
P26 Voltage
Defective R pump pres-
Between (B) and (A) Power supply 4.5 – 5.5 V
2 sure sensor (Internal
defect) Between (C) and (A) Signal 0.5 – 4.5 V
Pressure sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.
starting switch ON.
Disconnection of wiring Wiring harness between CP01 (female) (22) – A06 – Resistance
Max. 1 z
Presumed cause and
harness (Disconnection J25 – P26 (female) (B) value

3
or defective contact with Wiring harness between CP01 (female) (10) – J08 – Resistance
connector) Max. 1 z
A06 – P26 (female) (A) value
Wiring harness between CP01 (female) (2) – P26 Resistance
Max. 1 z
(female) (C) value
GND circuit) Wiring harness between CP01 (female) (2) – P26 Resistance
Min. 1 Mz
(female) (C) and chassis ground value
troubleshooting.
Wiring harness between CP01 (female) (22) – A06 –
5 with 24V circuit) in wiring Voltage Max. 1 V
J25 – P26 (female) (B)
harness
Wiring harness between CP01 (female) (2) – P26
Voltage Max. 1 V
(female) (C) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and start engine and
carry out troubleshooting in each case.
6 Defective pump controller CP01 Voltage
Between (22) and (10) 4.5 – 5.5 V
Between (2) and (10) 0.5 – 4.5 V
24 PC600-8
Circuit diagram related to R pump pressure sensor
PC600-8 25
Failure code [DV20KB] Travel Alarm S/C

Action code Failure code Failure Travel Alarm S/C
— DV20KB phenomenon (Pump controller system)
Failure content • Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit.
• Power to the travel alarm circuit is switched OFF.
Response from
controller
Phenomenon
occurring on • The travel alarm does not sound.
machine
Relative • Operation of the travel alarm (ON or OFF) can be checked in the monitoring function.
information (Code No. 03701: Controller output 2)

M14 (female) Travel lever Voltage
Travel alarm defective
1 Neutral Max. 1 V
(Internal defect)
Between (1) and (2)

Operated 20 – 30 V
Presumed cause and
If the above voltage is normal but the travel alarm does not operate, the travel alarm
is defective.
2
circuit) Min. 1 Mz
M14 (female) (1) and grounding value
3 Pump controller defective CP03 Travel lever Voltage
Neutral Max. 1 V
26 PC600-8
Circuit diagram related to travel alarm
PC600-8 27
Failure code [DW43KA] Travel Speed Sol. Disc.

Action code Failure code Failure Travel Speed Sol. Disc.
— DW43KA phenomenon (Pump controller system)
Failure content • No current flows to the travel speed select solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
Phenomenon
• The travel speed does not shift to Hi.
occurring on
(The swash plate angle of the travel motor is not minimized.)
machine
• The travel speed select solenoid is not turned ON when the engine speed is below 1,200 rpm.
• Operation of the travel speed select solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 02300: Solenoid 1)
information • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or
OFF, refer to the troubleshooting under failure code [DW43KB].)

Travel speed select position during the troubleshooting.
1 solenoid defective
V04 (male) Resistance value
(Internal disconnection)
Between (2) and (1) 20 – 60 z

Presumed cause and
harness
Wiring harness from CP03 (female) (27) to A05 and V04 Resistance
(female) (2) value
tor) Wiring harness between V04 (female) (1) to J23, A05, Resistance
Max. 1 z
J08, CP03 (female) (3), (13), (23), J13 and grounding value
Hot short (Short circuit position during the troubleshooting.
Voltage Max. 1 V
A05, and V04 (female) (2) and grounding
CP03 (female) Resistance value
Between (27) and grounding 20 – 60 z
28 PC600-8
Electrical circuit diagram related to travel speed select solenoid
PC600-8 29
Failure code [DW43KB] Travel Speed Sol. S/C

Action code Failure code Failure Travel Speed Sol. S/C
— DW43KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the travel speed select solenoid, when power was supplied to the circuit.
• Power supply to the travel speed select solenoid circuit is switched OFF.
Response from
controller
• The travel speed does not turn to Hi.
Phenomenon
(The swash plate angle of the travel motor is not minimized.)
occurring on
machine
• The travel speed select solenoid is not turned ON when the engine speed is below 1,200 rpm.
Relative
• Operation of the travel speed select solenoid (ON or OFF) can be checked in the monitoring function.
information
(Code No. 02300: Solenoid 1)

Travel speed select position during the troubleshooting.
solenoid defective V04 (male) Resistance value
1
(Internal short-circuiting
or grounding fault) Between (2) and (1) 20 – 60 z

Presumed cause and

2
(Contact with grounding Between wiring harness between CP03 (female) (27), Resistance
circuit) Min. 1 Mz
A05, and V04 (female) (2) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in high idling
during the troubleshooting.
3 Pump controller defective CP03 Travel speed select switch Voltage
Between (27) and Lo Max. 1 V
grounding Hi 20 – 30 V
30 PC600-8
Electrical circuit diagram related to travel speed select solenoid
PC600-8 31
Failure code [DW45KA] Swing Brake Sol. Disc.

Action code Failure code Failure Swing Brake Sol. Disc.
Failure content • No current flows in the swing holding brake solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it).
Phenomenon
occurring on • The machine cannot swing (The swing holding brake cannot be released).
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
• If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding
brake release switch in the RELEASE position (The parking brake does not operate when the machine
Relative stops, however).
information • Keep the swing lock switch in the OFF position and the swing holding brake release switch in the
RELEASE position during troubleshooting.
• Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the

Swing holding brake position during the troubleshooting.
Between (2) and (1) 20 – 60 z
Assembled-type diode position during the troubleshooting.
2 D01 defective
D01 (male) Digital tester Continuity
Between (7) and (3) Diode mode Continued
Swing lock switch
3 defective S04 (female) Swing lock switch Resistance value
OFF Max. 1 z
Between (3) and (4)
Presumed cause and
LOCK Min. 1 Mz
Wiring harness between CP03 (female) (37) and D01 Resistance
Disconnection of wiring Max. 1 z
(female) (7) value
harness
Wiring harness between D01 (female) (3), J04, and S04 Resistance
(male) (3) value
tor) Wiring harness between S04 (male) (4), V05 (female) Resistance
Max. 1 z
(2) value
Wiring harness between V05 (female) (1), J23, A05, J08 Resistance
Max. 1 z
and CP03 (female) (3), (13) and (23) value
harness Between wiring harness between CP03 (female) (37)
Voltage Max. 1 V
and D01 (female) (7)
6 Pump controller defective CP03 (female) Disconnect D01 and Resistance value
Between (37) and directly connect pins (3)
and (7) on the female side. 20 – 60 z
grounding
32 PC600-8
Electrical circuit diagram related to swing holding brake solenoid
PC600-8 33
Failure code [DW45KB] Swing Brake Sol. S/C

Action code Failure code Failure Swing Brake Sol. S/C
• Abnormal current flowed in the swing holding brake solenoid circuit, when power is supplied to the cir-
Failure content
cuit.
• Power to the swing holding brake solenoid circuit is switched OFF.
Response from
controller
Phenomenon
occurring on • The machine cannot swing (The swing holding brake cannot be released).
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
Relative
• If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding
information
brake release switch in the RELEASE position (The parking brake does not operate when the machine
stops, however).

Swing holding brake position during the troubleshooting.
1
2 D01 defective
Presumed cause and
D01 (male) Resistance value (Continuitiy)

(Internal short-circuiting)
Between (3) and (7) Min. 1 Mz (No continuitiy)
3
circuit) Min. 1 Mz
D01, J04, S04, and V05 (female) (2) and grounding value
Work equipment
CP03 Voltage
control lever
4 Pump controller defective Max. 1 V
All levers in neutral (5 sec after setting
Between (37) and in neutral)
grounding
Work equipment or
20 – 30 V
swing operated
34 PC600-8
Electrical circuit diagram related to swing holding brake solenoid
PC600-8 35
Failure code [DW48KA] CO Cancel Sol. Disc.

Action code Failure code Failure CO Cancel Sol. Disc.
Failure content • No current flows to the CO cancel solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
Phenomenon
• When the boom is raised and the machine travels, power is low (The pump CO function cannot be can-
occurring on
celled).
machine
• Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information

CO cancel position during the troubleshooting.
Between (2) and (1) 20 – 60 z

Presumed cause and
harness
(female) (2) value
Max. 1 z
J08, CP03 (female) (3), (13), (23) value
Voltage Max. 1 V
Pump controller position during the troubleshooting.
4
defective CP03 (female) Resistance value
36 PC600-8
Electrical circuit diagram related to CO cancel solenoid
PC600-8 37
Failure code [DW48KB] CO Cancel Sol. S/C

Action code Failure code Failure CO Cancel Sol. S/C
Failure content • Abnormal current flew to the CO cancel circuit, when power was supplied to the circuit.
• Power supply to the CO cancel circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
• When the boom is raised and the machine travels, power is low (The pump CO function cannot be can-
occurring on
celled).
machine
Relative • Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02300: Solenoid 1)

CO cancel solenoid position during the troubleshooting.
defective V07 (male) Resistance value
1

Presumed cause and

2
circuit) Min. 1 Mz
A05 and V08 (female) (2) and grounding value
Pump controller CP03 Swing lock switch Voltage
3
defective
Between (28) and OFF Max. 1 V
grounding ON (Note) 20 – 30 V
Note: May be measured under the condition of "Power max. switch ON (for 8.5 seconds)" or "Single boom
RAISE operation" or "Travel operation".
38 PC600-8
Electrical circuit diagram related to CO cancel solenoid
PC600-8 39
Failure code [DW7BKA] Fan Reverse Sol. Disc.

Action code Failure code Failure Fan Reverse Sol. Disc.
— DW7BKA phenomenon (Pump controller system)
Failure content • When signal is output to hydraulic drive solenoid circuit, no current flows.
Response from • None in particular (Since no current flows, solenoid does not operate).
monitor panel • If cause of failure disappears, system resets itself.
Phenomenon
occurring on • Fan does not rotate in reverse.
machine
Relative • Since disconnection of solenoid is detected while output is ON, be sure to turn output ON when check-
information ing for reproduction of failure after repair.

Defective hydraulic fan starting switch ON.
1 reverse solenoid (Internal
V17 (male) Resistance
disconnection)
Between (1) – (2) 20 – 60 z
starting switch ON.

Presumed cause and
harness (Disconnection Wiring harness between CP03 (female) (25) – V17
tact in connector) Wiring harness between V17 (female) (2) – CP03
Resistance Max. 1 z
(female) (3), (13), (23)
Hot short (Short circuit troubleshooting.
harness Wiring harness between CP03 (female) (25) – V17
Voltage Max. 1 V
starting switch ON.
CP03 (female) Resistance
Between (25) – chassis ground 20 – 60 z
Circuit diagram related to hydraulic fan
40 PC600-8
Failure code [DW7BKB] Fan Reverse Sol. S/C

Action code Failure code Failure Fan Reverse Sol. S/C
— DW7BKB phenomenon (Pump controller system)
Failure content • When signal was output to hydraulic fan reverse solenoid circuit, abnormal current flowed.
Response from • Turns output to hydraulic fan reverse solenoid circuit OFF.
monitor panel • If cause of failure disappears, system resets itself.
Phenomenon
occurring on • Fan does not rotate in reverse.
machine
• Operating condition (ON-OFF) of hydraulic fan reverse solenoid can be checked with monitoring func-
Relative
tion.
information

reverse solenoid (Internal V17 (male) Resistance
1
short circuit or ground
fault) Between (1) – (2) 20 – 60 z

Presumed cause and
Between (2) – chassis ground Min. 1 Mz

GND circuit) Wiring harness between CP03 (female) (25) – V17
troubleshooting.
3 Defective pump controller CP03 Working mode Voltage
Between (25) – Other than L-mode Max. 1 V
chassis ground L-mode 20 – 30 V
PC600-8 41
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc.

Action code Failure code Failure Bucket Curl Hi Cancel Sol. Disc.
— DW4XKA phenomenon (Pump controller system)
• Any current does not flow to the bucket Curl Hi cancel solenoid circuit, when power was supplied to the
Failure content
circuit.
Response from • None in particular (Since any current does not flow, the solenoid does not operate).
Phenomenon
• When the bucket and other work equipment are operated simultaneously, the speed of the other work
occurring on
equipment is low (The bucket Curl Hi function is not cancelled).
machine
• Operation of the bucket Curl Hi cancel solenoid (ON or OFF) can be checked in the monitoring function.
Relative
• Since the controller detects disconnection when the solenoid output is turned ON, be sure to turn the
information
solenoid output ON when checking for reproduction of the failure after repair. (For the method of check-
ing the ON/OFF state of the output, see troubleshooting for failure code [DW4XKB].)

Bucket Curl Hi cancel position during the troubleshooting.
Between (2) and (1) 20 – 60 z

Presumed cause and
harness (Disconnection Wiring harness between CP03 (female) (38), A05, and Resistance
2 Max. 1 z
or defective contact with V03 (female) (2) value
connector) Wiring harness between CP03 (female) (3), J08, and Resistance
Max. 1 z
V03 (female) (1) value
Voltage Max. 1 V
42 PC600-8
Electrical circuit diagram related to bucket curl Hi cancel solenoid
PC600-8 43
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C

Action code Failure code Failure Bucket Curl Hi Cancel Sol. S/C
— DW4XKB phenomenon (Pump controller system)
• Abnormal current flowed to the bucket Curl Hi cancel solenoid circuit, when power was supplied to the
Failure content
circuit.
• Power supply to the bucket Curl Hi cancel solenoid circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
• When the bucket and other work equipment are operated simultaneously, the speed of the other work
occurring on
equipment is low (The bucket Curl Hi function is not cancelled).
machine
Relative • Operation of the bucket Curl Hi cancel solenoid (ON or OFF) can be checked in the monitoring function.

Bucket Curl Hi cancel position during the troubleshooting.
1

Presumed cause and
grounding circuit) Between wiring harness between CP03 (female) (38), Resistance
Min. 1 Mz
Work equipment
CP03 Voltage
control lever
3 Pump controller defective All levers in neutral Max. 1 V
Between (38) and ground- Bucket Curl

ing +
20 – 30 V
Other work equipment
operation
44 PC600-8
Electrical circuit diagram related to bucket curl Hi cancel solenoid
PC600-8 45
Failure code [DWK0KA] 2-stage Relief Sol. Disc.

Action code Failure code Failure 2-stage Relief Sol. Disc.
— DWK0KA phenomenon (Pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
Phenomenon
• The heavy-lift function does not work.
occurring on
• Travel power is low (The main relief valve is not set in the HIGH PRESSURE position).
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information
OFF, refer to the troubleshooting under failure code [DWK0KB].)

2-stage relief solenoid position during the troubleshooting.
1 defective
Between (2) and (1) 20 – 60 z

Presumed cause and
harness
(female) (2) value
Max. 1 z
J08, CP03 (female) (3), (13), (23) value
Voltage Max. 1 V
46 PC600-8
Electrical circuit diagram related to 2-stage relief solenoid
PC600-8 47
Failure code [DWK0KB] 2-stage Relief Sol. S/C

Action code Failure code Failure 2-stage Relief Sol. S/C
— DWK0KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
controller
Phenomenon
occurring on • Travel power is low (The main relief valve is not set in the HIGH PRESSURE position).
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

2-stage relief solenoid position during the troubleshooting.
defective V08 (male) Resistance value
1

Presumed cause and

2
circuit) Min. 1 Mz
3 Pump controller defective CP03 Travel control lever Voltage
Between (17) and Neutral Max. 1 V
grounding Travel operation (Note) 20 – 30 V
Note: May be measured under the condition of "Power max. switch ON (for 8.5 seconds)" or "Single boom
RAISE operation".
48 PC600-8
Electrical circuit diagram related to 2-stage relief solenoid
PC600-8 49
Failure code [DX16KA] Fan Pump EPC Sol. Disc.

Action code Failure code Failure Fan Pump EPC Sol. Disc.
— DX16KA phenomenon (Pump controller system)
Failure content • No current flows in hydraulic fan EPC solenoid circuit.
Response from • None in particular (Since no current flows, solenoid does not operate).
Phenomenon
occurring on —
machine
Relative • Output (current) to hydraulic fan EPC solenoid can be checked with monitoring function.
information (Code No. 31623: Hydraulic fan EPC solenoid current)

1 EPC solenoid (Internal
V13 (male) Resistance
disconnection)
Between (1) – (2) 7 – 14 z
starting switch ON.
harness (Disconnection Wiring harness between CP03 (female) (35) – V13
Presumed cause and
tact in connector) Wiring harness between V13 (female) (2) – CP03
Resistance Max. 1 z
(female) (3), (13), (23)
troubleshooting.
Wiring harness between CP03 (female) (35) – V13
3 with 24 V circuit) in wiring Voltage Max. 1 V
harness
Wiring harness between V13 (female) (2) – CP03
Voltage Max. 1 V
(female) (3), (13), (23)
starting switch ON.
CP03 (female) Resistance
Between (35) – (3), (13), (23) 7 – 14 z
50 PC600-8
PC600-8 51
Failure code [DX16KB] Fan Pump EPC Sol. S/C

Action code Failure code Failure Fan Pump EPC Sol. S/C
— DX16KB phenomenon (Pump controller system)
Failure content • Abnormal current flowed in hydraulic fan EPC solenoid circuit.
Response from • Turns output to hydraulic fan EPC solenoid circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Phenomenon
occurring on —
machine
Relative • Output (current) to hydraulic fan EPC solenoid can be checked with monitoring function.
information (Code No. 31623: Hydraulic fan ECP solenoid current)

EPC solenoid (Internal V13 (male) Resistance
1
short circuit or ground
fault) Between (1) – (2) 7 – 14 z

Presumed cause and

GND circuit) Wiring harness between CP03 (female) (35) – V13
starting switch ON.
3 Defective pump controller CP03 (female) Resistance
Between (35) – (3), (12), (23) 7 – 14 z
52 PC600-8
PC600-8 53
Failure code [DXA0KA] TVC Sol. Disc.

Action code Failure code Failure TVC Sol. Disc.
E02 DXA0KA phenomenon (Pump controller system)
Failure content • No current flows in the TVC solenoid circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it).
Phenomenon
• If the pump load increases, the engine speed lowers extremely and the engine may stall.
occurring on
(The pump absorption torque cannot be controlled.)
machine
• Output to the TVC solenoid (current) can be checked in the monitoring function.
Relative (Code No. 01300: TVC solenoid current)
information • If the solenoid and wiring harness are normal, the machine can be operated with the output equivalent
to the E-mode by setting the emergency pump drive switch in the EMERGENCY position.

TVC solenoid defective position during the troubleshooting.
1
(Internal disconnection) V11 (male) Resistance value
Between (1) and (2) 10 – 22 z
Emergency pump
S25 (male) Resistance value
Emergency pump drive drive switch
2 switch defective NORML position Max. 1 z
(Internal disconnection) Between (2) and (3)
EMERGENCY position Min. 1 Mz
NORML position Max. 1 z
Between (5) and (6)
EMERGENCY position Min. 1 Mz

Presumed cause and
Wiring harness between CP03 (female) (16) and S25 Resistance
(female) (3) value
harness
Wiring harness between S25 (female) (2) and V11 Resistance
(female) (1) value
tor) Wiring harness between CP03 (female) (3) and S25 Resistance
Max. 1 z
(female) (6) value
Wiring harness between S25 (female) (5) and V11 Resistance
Max. 1 z
(female) (2) value
Between wiring harness between CP03 (female) (16)
4 with 24 V circuit) in wiring Voltage Max. 1 V
and S25 (female) (3) and grounding
harness
Between wiring harness between S25 (female) (2) and
Voltage Max. 1 V
V11 (female) (1) and grounding
Between (16) and (3) 10 – 22 z
54 PC600-8
Electrical circuit diagram related to TVC solenoid
PC600-8 55
Failure code [DXA0KB] TVC Sol. S/C

Action code Failure code Failure TVC Sol. S/C
E02 DXA0KB phenomenon (Pump controller system)
Failure content • Abnormal current flowed in the TVC solenoid circuit.
• Power to the TVC solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• If the pump load increases, the engine speed lowers extremely and the engine may stall. (The pump
occurring on
absorption torque cannot be controlled.)
machine
• Output to the TVC solenoid (current) can be checked in the monitoring function.
(Code No. 01300: TVC solenoid current)
Relative • If the solenoid and wiring harness are normal, the machine can be operated with the output equivalent
information to the E mode by setting the emergency pump drive switch in the EMERGENCY position (Failure code
[DXA0KA] is displayed at this time, but it does not indicate a failure).
• Keep the emergency pump drive switch in the normal position during troubleshooting.

TVC solenoid defective
1 (Internal short-circuiting V11 (male) Resistance value
Emergency pump drive

switch defective Emergency pump
Presumed cause and
2 S25 (male) Resistance value

(Internal short-circuiting drive switch
or grounding fault) Between (3) and (4) Min. 1 Mz
NORML position
harness Between wiring harness between CP03 (female) (16) Resistance
3 Min. 1 Mz
(Contact with grounding and S25 (female) (3) and grounding value
circuit) Between wiring harness between S25 (female) (2) and Resistance
Min. 1 Mz
V11 (female) (1) and grounding value
4 Pump controller defective CP03 (female) Resistance value
Between (16) and (3) 10 – 22 z
56 PC600-8
Electrical circuit diagram related to TVC solenoid
PC600-8 57
Failure code [DY20KA] Wiper Working Abnormality
Single wiper specification
Action code Failure code Failure Wiper Working Abnormality

— DY20KA phenomenon (Machine monitor system)
Failure content • A W signal is not inputted at both ends of movement, when it is in motion.
Response from
• Power to the wiper motor is turned OFF.
Monitor Panel
Phenomenon
occurring on • The wiper motor does not work.
machine
Relative • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
information (Code No.: 04502 Monitor input 3)

M05 (female) Windshield wiper blade Resistance value
Wiper motor defective
1 At upper end of operation
(Internal disconnection) Max. 1 z
range
Between (6) and (5)
Outside upper end of
Min. 1 Mz
operation range
Presumed cause and
harness Wiring harness between CM01 (female) (5) and M05 Resistance
2 Max. 1 z
(Disconnection or faulty (male) (6) value
contact with connector) Resistance
Wiring harness between M05 (male) (5) and grounding Max. 1 z
value
CM01 Wiper blade Voltage
Machine monitor
3 At upper end of
defective Max. 1 V
operation range
Outside upper end of
20 – 30 V
operation range
58 PC600-8
Electrical circuit diagram related to wiper motor (Single wiper specification.)
PC600-8 59
Failure code [DY20MA] Wiper Parking Abnormality
Double wiper specification
Action code Failure code Failure Wiper Parking Abnormality

— DY20MA phenomenon (Machine monitor system)
Failure content • P signal on the retraction range is not inputted, when the wiper is retracted.
Response from
• Power supply to the wiper motor is switched OFF, when the wiper is retracted.
Monitor Panel
Phenomenon
occurring on • The wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No.: 04502 Monitor input 3)

Upper wiper motor
1 defective M05 (female) Wiper blade Resistance value
(Internal disconnection) Retraction range Max. 1 z
Between (4) and (5)
Operation range Min. 1 Mz
Lower wiper motor
2 defective M15 (female) Wiper blade Resistance value
(Internal disconnection) Retraction range Max. 1 z
Between (4) and (5)
Presumed cause and

Wiring harness between CM01 (female) (12) and M05 Resistance
(male) (4) value
harness
Resistance
3 (Disconnection or defec- Wiring harness between M05 (male) (5) and grounding Max. 1 z
value
tor) Wiring harness between CM01 (female) (5) and M15 Resistance
Max. 1 z
(male) (4) value
Resistance
value
CM01 Upper wiper blade Voltage
Machine monitor Between (12) and Retraction range Max. 1 V

4 grounding
defective Operation range 20 – 30 V
CM01 Lower wiper blade Voltage
Retraction range Max. 1 V
Operation range 20 – 30 V
60 PC600-8
Electrical circuit diagram related to wiper motor (Double wiper specification.)
PC600-8 61
Action code Failure code Failure Wiper Parking Abnormality

— DY20MA phenomenon (Machine monitor system)
Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the wiper motor is switched OFF, when the wiper is
Monitor Panel retracted.
Phenomenon
occurring on • The wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No.: 04502 Monitor Input 3)

Wiper motor defective M05 (female) Wiper blade Resistance value
1
Retraction range Max. 1 z
Between (4) and (5)

Presumed cause and
harness
(male) (4) value
tor) Resistance
Between wiring harness M05 (male) (5) and grounding Max. 1 z
value
Machine monitor CM01 Wiper blade Voltage
3
defective
Between (12) and Retraction range Max. 1V
grounding Operation range 20 – 30 V
62 PC600-8
Electrical circuit diagram related to wiper motor (Single wiper specification.)
PC600-8 63
Failure code [DY2CKB] Washer Drive S/C

Action code Failure code Failure Washer Drive S/C
— DY2CKB phenomenon (Machine monitor system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power
Failure content
was switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine
Relative
—
information

Window washer drive position for the troubleshooting.
1 motor defective
M06 (male) Resistance value
Between (1) and (2) 5 – 20 z

Presumed cause and
2 with 24 V circuit) in wiring Between wiring harness from CM01 (female) (3) and
harness M06 (female) (2), or between wiring harness between Voltage Max. 1 V
CM01 (female) (3) and D04 (female) (6) and grounding
Machine monitor CM01 Window washer switch Voltage
3
defective
OFF 20 – 30 V
ON Max. 1 V
64 PC600-8
Electrical circuit diagram related to window washer motor
PC600-8 65
Failure code [DY2DKB] Wiper Drive (For) S/C
Action code Failure code Failure Wiper Drive (For) S/C

— DY2DKB phenomenon (Machine monitor system)
• Abnormal current flowed in the wiper motor forward rotation circuit, when power is supplied to the cir-
Failure content
cuit.
Response from
• Power to the wiper motor forward rotation circuit is switched OFF.
monitor panel
Phenomenon
occurring on • The wiper stops.
machine
Relative
—
information

Upper wiper motor position during the troubleshooting.
defective M05 (female) Continuity and resistance value
1
or grounding fault) Between (3) and (1) Continued
Lower wiper motor position during the troubleshooting.
defective M15 (female) Continuity and resistance value
2
or grounding fault) Between (3) and (1) Continued
Assembled-type diode
3 D04 defective D04 (male) Resistance value (Continuitiy)

Presumed cause and
(Internal short-circuiting) Between (3) and (7) Min. 1 Mz (No continuitiy)

Grounding fault of wiring Between wiring harness between CM01 (female) (9)
Resistance
harness and M05 (male) (3) or between CM01 (female) (9) and Min. 1 Mz
4 value
(Contact with grounding D04 (female) (3) and grounding
circuit) Between wiring harness between CM01 (female) (5),
Resistance
M15 (male) (3) or between CM01 (female) (5) and D04 Min. 1 Mz
value
(female) (4) and grounding
Machine monitor
defective CM01 Upper wiper switch Voltage
(Upper wiper motor) OFF Max. 3 V
ON 20 – 30 V (Note)
5
Machine monitor
defective CM01 Lower wiper switch Voltage
(Lower wiper motor) OFF Max. 3 V
ON 20 – 30 V (Note)
Note: When the upper wiper and lower wiper are operated simultaneously: Max. 3 V 20 – 30 V (at regular
intervals)
66 PC600-8
Electrical Circuit diagram related to wiper motor (Double wiper specification)
PC600-8 67
Action code Failure code Failure Wiper Drive (For) S/C

— DY2DKB phenomenon (Machine monitor system)
• Abnormal current flowed in the wiper motor forward rotation circuit, when power is supplied to the cir-
Failure content
cuit.
Response from
• Power to the wiper motor forward rotation circuit is switched OFF.
monitor panel
Phenomenon
machine
Relative
—
information

1 (Internal short-circuiting M05 (female) Continuity and resistance value
or grounding fault)
Between (3) and (1) Continued

Presumed cause and

2
circuit) Min. 1 Mz
and M05 (male) (3) and grounding value
Machine monitor CM01 Wiper switch Voltage
3
defective OFF Max. 3 V
Between (9) and grounding Max. 3 V 20 – 30 V
ON
(at constant cycle)
68 PC600-8
Electric circuit diagram related to wiper motor (Single wiper specification.)
PC600-8 69
Failure code [DY2EKB] Wiper Drive (Rev) S/C
Action code Failure code Failure Wiper Drive (Rev) S/C

— DY2EKB phenomenon (Machine monitor system)
• Abnormal current flowed in the wiper motor reverse rotation circuit, when power is supplied to the cir-
Failure content
cuit.
Response from
• Power to the wiper motor reverse rotation circuit is switched OFF.
monitor panel
Phenomenon
machine
Relative
—
information

position for the troubleshooting.
1 (Internal short-circuiting M05 (female) Continuity and resistance value
or grounding fault)

Presumed cause and

2
circuit) Min. 1 Mz
and M05 (male) (1) and grounding value
3
defective OFF Max. 3 V
Between (10) and
grounding Max. 3 V 20 – 30 V
ON
(at constant cycle)
70 PC600-8
Electric circuit diagram related to wiper motor (Single wiper specification.)
PC600-8 71
©2006 KOMATSU
All Rights Reserved
72
UEN00451-00
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 K50001 and up

40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Troubleshooting of electrical system (E-mode) .................................................................................................... 4

Before Carrying Out Troubleshooting E-MODE.............................................................................................. 4
Information Contained in Troubleshooting Table ............................................................................................ 6
E-1 Engine does not start (Engine does not rotate)........................................................................................ 8
E-2 Preheater does not operate ................................................................................................................... 12
E-3 Auto engine warm-up device does not work .......................................................................................... 14
E-4 Auto-decelerator does not operate ........................................................................................................ 15
E-5 All work equipment, swing and travel do not move ................................................................................ 16
E-6 Power max. function does not operate .................................................................................................. 18
E-7 Machine push-up function does not operate normally ........................................................................... 19
E-8 Any item is not displayed on machine monitor....................................................................................... 21
E-9 Part of display on machine monitor is missing ....................................................................................... 22
E-10 Machine monitor displays contents irrelevant to the model ................................................................. 22
E-11 Fuel level monitor red lamp lights up while engine is running .............................................................. 23
E-12 Engine coolant temperature gauge does not display correctly ............................................................ 24
E-13 Hydraulic oil temperature gauge does not display correctly ................................................................ 26
E-14 Fuel gauge does not display correctly ................................................................................................. 27
E-15 Swing lock monitor does not display correctly ..................................................................................... 28
E-16 When monitor switch is operated, nothing is displayed ....................................................................... 30
E-17 Wiper and window washer do not work ............................................................................................... 32
E-18 "Boom Raise" is not correctly displayed in monitoring function ........................................................... 40
E-19 "Boom Lower" is not correctly displayed in monitoring function........................................................... 41
PC600-8 1
E-20 "Arm IN" is not correctly displayed in monitoring function .................................................................... 42

E-21 "Arm OUT" is not correctly displayed in monitoring function ................................................................ 43
E-22 "Bucket CURL" is not correctly displayed in monitoring function ......................................................... 44
E-23 "Bucket DUMP" is not correctly displayed in monitoring function ........................................................ 45
E-24 "Swing" is not correctly displayed in monitoring function ..................................................................... 46
E-25 "Travel" is not correctly displayed in monitoring function ..................................................................... 48
E-26 Air conditioner does not work............................................................................................................... 50
E-27 Step light does not light up or go off..................................................................................................... 52
E-28 Electric grease gun does not operate .................................................................................................. 56
E-29 Travel alarm does not sound or does not stop sounding ..................................................................... 58
2 PC600-8
PC600-8 3
Troubleshooting of electrical system (E-mode)

Before Carrying Out Troubleshooting E-MODE
Connection table of circuit breakers

a This connection table shows the devices to which each power supply of the circuit breakers supplies power
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
first to see if the power is supplied normally.
Type of power Circuit breaker Circuit breaker

Destination of power
supply No. capacity
1 40A Fuse box (Fuses No. 1 – 15)
Switch power 2 20A Boom working lamp, right head lamp
supply (Battery relay 3 20A Grease pump
terminal M) 4 20A Pump controller power source
5 20A Head lamp on cab
Constant power 6 20A Starting switch, Pump controller (Power supply for solenoid)
supply 7 30A Engine controller power supply relay (Power supply drive)
(Battery relay 8 20A Machine monitor, buzzer
terminal B) 9 20A Fuse box (Fuses No. 16 – 20)
4 PC600-8
Connection table of fuse boxes

a This connection table shows the devices to which each power supply of the fuse boxes supplies power (A
switch power supply is a device which supplies power while the starting switch is at the ON position and a
constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting for a displayed code, you should check the fuse boxes to see if the
Type of power
Fuse No. Fuse capacity Destination of power
supply
TVC solenoid (for emergency pump drive)
1 10A
Swing holding brake solenoid (for swing brake release)
2 10A Boom stabilizer solenoid
Switch power PPC lock solenoid
3 10A
supply Starting motor cut relay
(Circuit breaker 1) Cigarette lighter
4 20A
Windshield washer motor
Horn
5 10A
Flash light
6 10A Intake air heater
Switch power 7 10A Rotary lamp
(Circuit breaker 1) 9 10A Radio, Power max. switch
10 20A Machine monitor, Buzzer
11 25A Air conditioner unit
Switch power 12 20A (Spare)
(Circuit breaker 1) 14 10A Service power supply (M32 connector)
15 10A DC/DC converter (12 V)
16 10A Radio backup
17 10A (Spare)
Constant power 18 10A (Spare)
supply 19 10A Room lamp
(Circuit breaker 9) Step light
20 10A Pump controller power source (for step light)
Step light switch
PC600-8 5
Information Contained in Troubleshooting Table
a The following information are edited and contained in the "Information Contained in Troubleshooting Table".
You are required to proceed with troubleshooting after fully grasping the contents.
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge "good" or "no good" about pre-
1 sumed causes.
• References for making judgement of "good" or "no good"
<Phenomena of wiring harness fault>

• Failure due to disconnection
Defective contact with connector or disconnection of wiring harness has occurred.
2
• Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in contact
Presumed cause and
with it.
Cause for presumed • Hot short
failure Wiring harness which is not connected to power source (24 V) circuit is in contact
(The attached No. for with power source (24 V) circuit.
3
filing and reference
purpose only. It does not <Points to remember in troubleshooting>
stand for any priority) 1) Connector denotation method and handling of T-adapters
Insert or connect T-adapters in the following manner, unless specifically otherwise
instructed.
• If there is no indication of (male) or (female) in the connector No., pull off a con-
4
nector and insert a T-adapter into both sides of male and female.
• If there is an indication of (male9 and (female) in the connection No., pull off a
connector and insert a T-adapter into only one side of (male) or (female).
2) Description sequence of pin No. and handling of circuit tester leads
Connect the positive lead (+) and negative lead (–) for troubleshooting in the fol-
5 lowing manner unless specifically otherwise instructed.
• Connect the positive lead (+) to a pin No. marked at the front or wiring harness.
• Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.
6 PC600-8
Related circuit diagram
This drawing is a part of the electric circuit diagram related to

troubleshooting.
• Connector No.: Indicates (Model – Number of pins) and
(Color).
• "Connector No. and pin No." from each branching/merging
point: Shows the ends of branch or source of merging within
the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the machine.
PC600-8 7
E-1 Engine does not start (Engine does not rotate)

Failure
• The engine does not start. (Engine does not rotate)
information
Relative
• The engine starting circuit is equipped with the start lock mechanism of work equipment lock lever type.
information

Battery capacity position during the troubleshooting.
1
insufficient Battery voltage Electrolyte specific gravity
Min. 24 V Min. 1.26
Circuit breakers No. 1 or If a circuit breaker is turned OFF or a fuse is broken, the circuit probably has ground-
2
6 or fuse 2, 3, 6 defective ing fault (See cause 9).
position or start the engine during the troubleshooting.
Starting switch defective M06 (male) Starting switch Resistance value
3
OFF Min. 1 Mz
Between (1) and (4)
ON Max. 1 z
Work equipment lock
4 switch defective S14 (female) Work equipment lock lever Resistance value
FREE Min. 1 Mz
Between (1) and (3)
Presumed cause and
LOCK Max. 1 z
Starting motor cut-out R06 (female) and R07 (female) Resistance value
5 relay defective
Between (1) and (2) 100 – 500 z
(Internal defect)
Between (3) and (5) Min. 1 Mz
Between (3) and (6) Max. 1 z
a Turn the engine starting switch OFF for the preparations (with the wiring harness
connected), and start the engine for troubleshooting.
Starting motor Voltage
B (Power
Between B and grounding 20 – 30 V
supply)
Starting motor defective
6 Between ST (1)
(Internal defect) S (Start) 20 – 30 V
and grounding
Between ST (2)
R (Charge) Max. 1 V
and grounding
If the above voltages are normal and the starting motor does not rotate, the starting
motor has a defect in it or the engine is defective.
a Turn the engine starting switch OFF for the preparations (with only wiring harness
Alternator defective R disconnected), and hold it in the ON position during the troubleshooting.
7
(Internal short-circuiting) Alternator Voltage
Between terminal R and grounding Max. 1 V
8 PC600-8

Wiring harness between battery relay terminal B and Resistance
Max. 1 z
B16 value
Resistance
Wiring harness between B26 and H06 (female) (1) Max. 1 z
value
Wiring harness between H06 (female) (4) and R06 Resistance
(female) (5) value
harness
Wiring harness between R06 (female) (3) and ST Resistance
(female) (1) value
tor) Resistance
Wiring harness between F01-3 and S14 (male) (1) Max. 1 z
value
Wiring harness between S14 (male) (3) and R06 Resistance
Max. 1 z
(female) (1) value
Wiring harness between R06 (female) (2) and R07 Resistance
Max. 1 z
(female) (6) value
Presumed cause and
Wiring harness between R07 (female) (3), J04, A07 and Resistance
Max. 1 z
grounding value
Between wiring harness between B26 and H06 (female) Resistance
Min. 1 Mz
(1) and grounding value
Between wiring harness between H06 (female) (4) and Resistance
Min. 1 Mz
R06 (female) (5) and grounding value
Grounding fault of wiring Between wiring harness between R06 (female) (3) and Resistance
Min. 1 Mz
harness ST (female) (1) and grounding value
9
(Contact with grounding Between wiring harness between F01-3 and S14 (male) Resistance
circuit) Min. 1 Mz
(1) and grounding value
Between wiring harness between S14 (male) (3) and Resistance
Min. 1 Mz
Between wiring harness between R06 (female) (2) and Resistance
Min. 1 Mz
Between wiring harness between R06 (female) (2) and Resistance
Min. 1 Mz
CM02 (female) (14) and grounding value
10 with 24 V circuit) in wiring Between wiring harness between ST (female) (2) and
harness alternator terminal R or between ST (female) (2), J02
Voltage Max. 1 V
and D01 (female) (6) or between ST (female) (2) and
CM02 (female) (11) and grounding
PC600-8 9
Electrical circuit diagram for engine preheating, starting, charging
10 PC600-8
PC600-8 11
E-2 Preheater does not operate

Failure (1) When the starting switch is turned to the HEAT posi-
• The preheater does not operate.
information tion, the preheating monitor does not light up.
• The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about
Relative 30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds).
information • Input of the preheating signal (ON or OFF) can be checked in the monitoring function.

Starting switch system If the preheater does not operate (the heater unit is not warmed), carry out trouble-
1
defective shooting (2).
Presumed cause and

tive contact with connec- Wiring harness between CM02 (female) (18) and J02 Resistance
Max. 1 z
tor) (male) (7) value
a Turn the engine starting switch OFF for the preparations , and hold it in the OFF or
HEAT position during troubleshooting.
Machine monitor CM02 Starting switch Voltage
3
defective
Between (18) and OFF Max. 1 V
grounding HEAT 20 – 30 V
Failure (2) When the starting switch is turned to the HEAT

• The preheater does not operate.
information position, the heater unit is not warmed.
Relative • Check that the starting motor rotates normally.
information • (If the starting motor does not rotate, carry out troubleshooting in "Engine does not start".)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF or
HEAT position during troubleshooting.
Starting switch defective H06 (male) Starting switch Resistance value
1
OFF Min. 1 Mz
Between (1) and (3)
HEAT Max. 1 z
a Turn the engine starting switch OFF for the preparations (with the wiring harness
connected), and hold it in the OFF or HEAT position during troubleshooting.
Continuity and
Heater relay defective Heater relay Starting switch

2 resistance value
Presumed cause and
Between coil terminal
OFF Continued
and grounding
Between contact terminals HEAT Max. 1 z
Intake air heater position during the troubleshooting.
3 defective
Intake air heater Continuity
Between terminals Continued
Wiring harness between H06 (female) (3), J02, and Resistance
Max. 1 z
heater relay terminal R17 value
Disconnection of wiring Wiring harness between battery relay terminal B and Resistance
harness Max. 1 z
heater relay R15 value
tive contact with connec- Wiring harness between heater relay terminal R16 and Resistance
Max. 1 z
tor) intake air heater value
Resistance
Wiring harness between intake air heater and engine Max. 1 z
value
12 PC600-8
Electrical circuit diagram for engine preheating, starting, charging
PC600-8 13
E-3 Auto engine warm-up device does not work

Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine coolant temperature is below 30°C, and
raise the engine rotation up to 1,200 rpm.
Relative • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
information than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.
• If the engine coolant temperature is below 10°C, the turbocharger protection function operates to keep
the engine speed below 1,000 rpm for up to 5 seconds after the engine is started.

a Turn the starting switch ON for the troubleshooting (monitoring).

Presumed cause and
Monitoring code Item Normal display
Engine coolant Compare the monitor

1 Engine coolant temperature
temperature signal fault 04107 indication with the actual
(low temperature)
engine coolant temperature.
If the display on the machine monitor is abnormal, carry out troubleshooting in "E-12
Engine coolant temperature gauge does not display correctly".
Engine controller If cause 1 is not detected, the engine controller may be defective. (Since trouble is in
2
defective the engine controller, troubleshooting cannot be carried out.)
14 PC600-8
E-4 Auto-decelerator does not operate

Failure
• The auto-decelerator does not operate.
information
• Since the auto-decelerator is set to 1,400 rpm, it does not operate if the fuel control dial is not set above
this level.
Relative
• Check the display on the monitor panel while the engine is running.
information
• If the display on the monitor panel is abnormal, carry out troubleshooting in E-18 to E-25 " is not
displayed normally in monitoring function".

Boom RAISE signal
1 01900 Lever operated: ON
defective Boom RAISE
Pressure switch 1 Lever in neutral: OFF
Boom LOWER signal
defective Boom LOWER
3 Arm IN signal defective 01900 Lever operated: ON
Arm IN
4 Arm OUT signal defective 01900 Lever operated: ON
Arm OUT

Presumed cause and

Bucket CURL signal
defective Bucket CURL
Bucket DUMP signal
defective Bucket DUMP
7 Swing signal defective 01900 Lever operated: ON
Swing
8 Travel signal defective 01900 Lever operated: ON
Right travel
9 Service signal defective 01901 Lever operated: ON
Service
If causes 1 – 9 are not detected, the pump controller may be defective.
(Since trouble is in the pump controller, troubleshooting cannot be carried out.)
Engine controller If causes 1 – 9 are not detected, the engine controller may be defective.
11
defective (Since trouble is in the pump controller, troubleshooting cannot be carried out.)
PC600-8 15
E-5 All work equipment, swing and travel do not move

Failure
• All the work equipment, swing and travel do not move.
information
Relative
—
information

If the fuse is blown, there is a big possibility that grounding fault occurred in the cir-
1 Fuse No. 3 fault
cuit. (See cause 6.)
Safety lock switch
2 defective S14 (female) Safety lock lever Resistance value
(Internal disconnection) Free Max. 1 z
Between (1) and (2)
Lock Min. 1 Mz
PPC lock solenoid defec-
tive
3 (Internal disconnection, V01 (male) Resistance value
short-circuiting, or Between (2) and (1) 20 – 60 z
grounding fault)
Presumed cause and
4 D01 defective
Disconnection of wiring Resistance
harness Wiring harness between F01-3 outlet and S14 (male) (1) Max. 1 z
value
tive contact with connec- Wiring harness from S14 (male) (2) and V01 (female) Resistance
Max. 1 z
tor) (2) value
Resistance
Wiring harness between V01 (female) (1) and grounding Max. 1 z
value
Between wiring harness between F01-3 outlet and S14 Resistance
harness Min. 1 Mz
6 (male) (1) and grounding value
(Contact with grounding
circuit) Wiring harness from S14 (male) (2) to V01 (female) (2),
Resistance
or between wiring harness between S14 (male) (2) and Min. 1 Mz
value
D01 (female) (4) and grounding
16 PC600-8
Electrical circuit diagram for PPC lock solenoid
PC600-8 17
E-6 Power max. function does not operate

Failure
• Power max. function does not operate
information
• If the power max. switch is pressed while the engine is running, the power max. monitor is displayed on
Relative the monitor panel.
information • Input condition of the power max. switch (left knob switch) (ON or OFF) can be checked in the monitor-
ing function. (Code No. 02200: Switch input 1)

If the fuse is broken, there is a big possibility that grounding fault occurred in the cir-
1 Fuse No. 9 defective
cuit. (See cause 4.)
Power max. switch defec-
2 tive (Internal disconnec- M23 (male) Power max. switch Resistance value
tion) Released Min. 1 Mz
Between (1) and (2)
Pressed Max. 1 z
Presumed cause and
harness (Disconnection position during the troubleshooting.
3
or defective contact with Wiring harness between F01-9 outlet and S11 (female) Resistance
connector) Max. 1 z
(1) value
Between wiring harness between F01-9 outlet and S11 Resistance
4 harness (Contact with Min. 1 Mz
(female) (1) and grounding value
grounding circuit)
Between wiring harness between S11 (female) (2) and Resistance
Min. 1 Mz
CP01 (female) (11) and grounding value
5 Pump controller defective CP01 Power max. switch Voltage
Between (11) and Released Max. 1 V
grounding Pressed 20 – 30 V
Electrical circuit diagram related to power max. switch
18 PC600-8
E-7 Machine push-up function does not operate normally

Failure • Machine push-up function does not operate
(1) The machine push-up function does not operate.
information normally.
Relative
• When the machine push-up function is set in the high pressure position, the solenoid is turned OFF.
information


Presumed cause and
Machine push-up switch

1 defective S05 (female) Machine push-up switch Resistance value
(Internal short-circuiting) Low pressure position Max. 1 z
Between (1) and (2)
High pressure position Min. 1 Mz
Hot short (Short circuit position during troubleshooting.
2 with 24 V circuit) in wiring Between wiring harness between S05 (male) (2), J01
harness and V06 (female) (2) or between S05 (male) (2) and Voltage Max. 1 V
Electrical circuit diagram related to machine push-up solenoid
PC600-8 19
Failure • Machine push-up function does not operate

(2) The machine push-up function is not turned OFF.
information normally.
Relative
• When the machine push-up function is set in the low pressure position, the solenoid is turned ON.
information

1 Fuse No. 2 defective If the fuse is broken, the circuit probably has grounding fault (See cause 6).
Machine push-up switch
2 defective S05 (female) Machine push-up switch Resistance value
(Internal disconnection) Low pressure position Max. 1 z
Between (1) and (2)
High pressure position Min. 1 Mz
Machine push-up
solenoid defective
3 (Internal disconnection, V06 (male) Resistance value
short-circuiting or Between (2) and (1) 20 – 60 z
grounding fault)
Presumed cause and
Assembled-type diode position during troubleshooting.

4 D03 defective
Disconnection of wiring Resistance
harness Wiring harness between F01-2 outlet and S05 (male) (1) Max. 1 z
value
tive contact with connec- Wiring harness between S05 (male) (2), J01 and V06 Resistance
Max. 1 z
Resistance
Wiring harness between V06 (female) (1) and grounding Max. 1 z
value
Grounding fault of wiring Between wiring harness between F01-2 outlet and S05
Resistance
harness (male) (1) or between F01-2 outlet and related circuits Min. 1 Mz
6 value
(Contact with grounding and grounding
circuit) Between wiring harness between S05 (male) (2), J01
Resistance
and V06 (female) (2) or between S05 (male) (2) and Min. 1 Mz
value
20 PC600-8
E-8 Any item is not displayed on machine monitor

Failure • Any item is not displayed on the machine When the starting switch is turned ON, any item is not
information monitor. displayed on the machine monitor.
Relative
information

Circuit breaker No. 1 or If the circuit breaker is turned OFF or the fuse is broken, the circuit probably has
1
fuse No. 10 defective grounding fault (See cause 3).
Disconnection of wiring Wiring harness between CM01 (female) (1), (2) and Resistance
harness Max. 1 z
F01-10 outlet value
tive contact with connec- Resistance
Wiring harness between F01 inlet and B21 Max. 1 z
tor) value
Presumed cause and
Wiring harness between B11 and battery relay terminal Resistance

Max. 1 z
M value
harness Between wiring harness between CM01 (female) (1), (2) Resistance
3 Min. 1 Mz
(Contact with grounding and F01-10 outlet and grounding value
circuit) Between wiring harness between F01 inlet and B21 and Resistance
Min. 1 Mz
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON or
OFF position during troubleshooting.
CM01 (female) Starting switch Voltage, Resistance value
Machine monitor
4 Between (1), (2)
defective ON Voltage: 20 – 30 V
and grounding
Between (6), (7) Resistance value:
OFF
and grounding Max. 1 z
Electrical circuit diagram related to machine monitor power supply
PC600-8 21
E-9 Part of display on machine monitor is missing

Failure Part of the display in the machine monitor is missing
• Part of display on machine monitor is missing
information during starting switch in ON.
Relative
—
information

Presumed cause and
a Turn the starting switch ON during the troubleshooting.
Machine monitor LCD If all the LCD (Liquid Crystal Display) in the machine monitor light up (i.e. the screen
1 becomes totally white) by the following switching operation, then the machine moni-
fault
tor is normal.
• Switching operation: [ ] + [ A ] (push swiches simultaneously.)
Machine monitor If cause 1 is not detected, the machine monitor may be defective. (Since trouble is in
2
defective the machine monitor, troubleshooting cannot be carried out.)
E-10 Machine monitor displays contents irrelevant to the model

Failure
• The machine monitor displays contents that have nothing to do with the model on which it is installed.
information
Relative
—
information

Presumed cause and
a Turn the starting switch in ON during the troubleshooting (monitoring).
Model code signal fault Monitoring code Item Normal display

1
(Internal failure) 00200 Controller model code PC600-a
If the display on the monitor panel is normal, troubleshoot failure code [DA2SKQ].
Machine monitor If cause 1 is not detected, the machine monitor may be defective. (Since trouble is in
2
defective the machine monitor, troubleshooting cannot be carried out.)
22 PC600-8
E-11 Fuel level monitor red lamp lights up while engine is running
Failure
• Fuel level monitor red lamp lighted up while the engine was running.
information
Relative
• If the fuel gauge shows in a red range on the machine monitor, the fuel level monitor lamp lights up red.
information

Fuel level lowered
1 (system in normal Check the fuel level in the fuel tank. If it is low, add fuel.
condition)
Fuel level sensor fault P21 (male) Fuel level Resistance value
2
Presumed cause and
FULL (Upper limit) Approx. 12 z
EMPTY (Lower limit) 85 – 110 z
tive contact with connec- Wiring harness between CM02 (female) (2) and P21 Resistance
Max. 1 z
Machine monitor CM02 (female) Fuel level Resistance value
4
defective
Electrical circuit diagram related to fuel level sensor
PC600-8 23
E-12 Engine coolant temperature gauge does not display correctly

(1) While the engine coolant temperature rises normally,
the temperature gauge does not rise above the white
Failure • Engine coolant temperature gauge does not range (C).
information display correctly (2) While the engine coolant temperature is stabilized
normally, the temperature gauge rises up to the red
range (H).
• The signal of the engine coolant high temperature sensor for the coolant temperature gauge is received
from the engine controller through the communication line.
• If the engine coolant high temperature sensor system becomes defective, failure code [CA144] may be
Relative
displayed.
information
• Input from the engine coolant high temperature sensor (voltage and temperature) can be checked in the
monitoring function. (Code No. 04106: Engine coolant sensor voltage Hi, Code No. 04102: Engine
coolant temperature (High temperature))

Engine coolant high a Turn the engine starting switch OFF for the preparations, and turn to ON or keep
temperature sensor the engine running during the troubleshooting.
defective TWTR (male) Resistance value
1
(Internal disconnection,
short-circuiting or Between (A) and (B) 3.5 k – 90 kz
grounding fault) Between (A), (B) and grounding Min. 1 Mz
harness
Wiring harness between ENG (female) (15) and TWTR Resistance
(female) (1) value

Wiring harness between ENG (female) (38), JM03 and Resistance
Presumed cause and
tor) Max. 1 z
TWTR (female) (2) value
3
(Contact with grounding Between wiring harness between ENG (female) (15) Resistance
circuit) Min. 1 Mz
and TWTR (female) (1) and grounding value
harness Between wiring harness between ENG (female) (15)
Voltage Max. 1 V
and TWTR (female) (1) and grounding
Engine controller ENG (female) Resistance value
5
defective
Between (15) and (38) 3.5 k – 90 kz
Between (15), (38) and grounding Min. 1 Mz
Machine monitor If causes 1 – 5 are not detected, the monitor panel may be defective. (Since trouble
6
defective is in the monitor panel, troubleshooting cannot be carried out.)
24 PC600-8
Electrical circuit diagram related to engine coolant high temperature sensor
PC600-8 25
E-13 Hydraulic oil temperature gauge does not display correctly

• Hydraulic oil temperature rises normally, but the dis-
Failure • Hydraulic oil temperature gauge does not display does not exceed the white range (C).
information play correctly • Hydraulic oil temperature remains stable, but the dis-
play rises up the red range (H).
Relative • Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
information (Code No. 04401: Hydraulic oil temperature)

Hydraulic oil temperature
sensor defective
1 (Internal disconnection, P22 (male) Hydraulic oil temperature Resistance value
short-circuiting or Between (1) and (2) 90 – 3.5 kz
grounding fault) 10 – 100°C
Presumed cause and standard value in normalcy
harness
(female) (1) value
tor) Wiring harness between CM02 (female) (13) and P22 Resistance
Max. 1 z
(female) (2) value
3
(GND) circuit) Min. 1 Mz
harness Between wiring harness between CM02 (female) (12)
Voltage Max. 1 V
and P22 (female) (1) and grounding
Machine monitor CM02 (female) Hydraulic oil temperature Resistance value
5
defective Between (12) and (13) 90 – 3.5 kz
Between (12) and 10 – 100°C
Min. 1 Mz
grounding
Electrical circuit diagram related to hydraulic oil temperature sensor
26 PC600-8
E-14 Fuel gauge does not display correctly

• Though fuel was refilled, the display does not exceed
Failure the red range (E).
• Fuel gauge does not display correctly
information • Though the remaining fuel level is low, the display
does not drop below the green range (F).
Relative • Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
information (Code No. 04200: Fuel sensor voltage)

Fuel level sensor defec- position during the troubleshooting.
tive P21 (male) Fuel level Resistance value
1
grounding fault) FULL (Upper limit) Approx. 12 z
Presumed cause and
tive contact with connec- Max. 1 z

3
(Contact with grounding Between wiring harness between CM02 (female) (2) and Resistance
P21 (female) (1) and grounding value
harness Between wiring harness between CM02 (female) (2) and
Voltage Max. 1 V
P21 (female) (1) and grounding
Machine monitor CM02 (female) Fuel level Resistance value
5
defective
Electrical circuit diagram related to fuel level sensor
PC600-8 27
E-15 Swing lock monitor does not display correctly

(1) Though the swing lock switch was turned ON, the
Failure swing lock monitor does not light up.
• Swing lock monitor does not display correctly
information (2) Though the swing lock switch was turned OFF, the
swing lock monitor lights up.
Relative • Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.
information (Code No.: 04502 Monitor input 3)

Swing lock switch defec- position during the troubleshooting.
tive S04 (female) Swing lock switch Resistance value
1
short-circuiting) OFF Min. 1 Mz
Between (1) and (2)
ON Max. 1 z
harness
Wiring harness from CM02 (female) (17) to J07 and S04 Resistance
(male) (1) value

Presumed cause and
tor) Wiring harness from S04 (male) (2) to J03 and ground- Resistance
Max. 1 z
ing value
harness
3 Between wiring harness from CM02 (female) (17) to J07
(GND) circuit) and S04 (male) (1), or between CM02 (female) (17) to Min. 1 Mz
value
CP02 (female) (38) and grounding
4 with 24 V circuit) in wiring Between wiring harness from CM02 (female) (17) to J07
harness and S04 (male) (1), or between CM02 (female) (17) to Voltage Max. 1 V
CP02 (female) (38) and grounding
Machine monitor CM02 Swing lock switch Voltage
5
defective
Between (17) and OFF 20 – 30 V
grounding ON Max. 1 V
28 PC600-8
Electrical circuit diagram related to swing holding brake
PC600-8 29
E-16 When monitor switch is operated, nothing is displayed

Failure • When monitor switch is operated, nothing is (1) When mode selector switch is operated, working
information displayed. mode monitor is not displayed.
Relative
—
information
Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Machine monitor
1 As this is an internal failure, troubleshooting cannot be conducted.
in normalcy defective
Failure • When monitor switch is operated, nothing is (2) When LCD monitor adjustment switch is operated,
information displayed. mode selection screen is not displayed.
Relative
—
information

cause and
Failure • When monitor switch is operated, nothing is (3) When maintenance switch is operated, item selec-
information displayed. tion screen is not displayed.
Relative
—
information

cause and
Failure • When monitor switch is operated, nothing is (4) When auto-deceleration switch is operated, auto-
information displayed. matic deceleration monitor is not displayed.
Relative • When the automatic decelerator does not operate either, conduct the troubleshooting for "Auto-deceler-
information tor does not operate".

cause and
Failure • When monitor switch is operated, nothing is (5) When travel speed selector switch is operated,
information displayed. travel speed monitor is not displayed.
Relative
information

cause and
30 PC600-8
Failure • When monitor switch is operated, nothing is (6) When wiper switch is operated, wiper monitor is not
information displayed. displayed.
Relative • When the wiper does not operate either, conduct the troubleshooting for "Windshield wiper and window
information washer do not work".

cause and
PC600-8 31
E-17 Wiper and window washer do not work
Failure
• Wiper and window washer do not work (1) Upper wiper does not operate
information
Relative
—
information

Upper wiper motor position during the troubleshooting.
1 defective
M05 (female) Continuity and resistance value

Presumed cause and
harness
(male) (3) value
tor) Resistance
value
3
defective
OFF Max. 3 V
ON 20 – 30 V (Note)
intervals)
32 PC600-8
PC600-8 33
Failure
• Wiper and window washer do not work (2) Lower wiper does not operate.
information
Relative
—
information

Lower wiper switch
1 defective S08 (female) Lowe wiper switch Resistance value
(Internal disconnection) OFF Min. 1 Mz
Between (1) and (2)
ON Max. 1 z
Lower wiper motor position during the troubleshooting.
2 defective
M15 (female) Continuity and resistance value

Presumed cause and
Wiring harness between CM02 (female) (15) and S08 Resistance

(male) (1) value
harness
Wiring harness between S08 (male) (2), J05 and Resistance
grounding value
tor) Wiring harness between CM01 (female) (10), J02 and Resistance
Max. 1 z
M15 (male) (3) value
Wiring harness between M15 (male) (1), J05 and Resistance
Max. 1 z
grounding value
Machine monitor defec-
tive (Lower wiper switch CM02 Lower wiper switch Voltage
system) Between (15) and OFF 20 – 30 V
grounding ON Max. 1 V
4
Machine monitor defec-
tive (Lower wiper motor CM01 Lower wiper switch Voltage
system) Between (10) and OFF Max. 3 V
grounding ON 20 – 30 V (Note)
intervals)
34 PC600-8
Electrical circuit diagram related to wiper motor (double wiper specification)
PC600-8 35
Failure
• Wiper and window washer do not work. (3) Wiper does not work.
information
Relative
—
information

Window rear limit switch position during the troubleshooting.
defective S12 (female) Front window Resistance value
1
short-circuiting) When installed at front Min. 1 Mz
Between (1) and (2)
When retracted at rear Max. 1 z
Wiper motor defective position during the troubleshooting.
2
(Internal disconnection) M05 (female) Continuity and resistance value
harness
Wiring harness between CM01 (male) (9) and M05 Resistance
Presumed cause and

(female) (3) value
tor) Wiring harness between CM01 (male) (10) and M05 Resistance
Max. 1 z
(female) (1) value
4
circuit) Min. 1 Mz
and S12 (male) (2) value
Machine monitor position during the troubleshooting.
defective CM02 Front window Voltage
(Window rear limit switch
system) Between (15) and When installed at front 20 – 30 V
grounding When retracted at rear Max. 1 V
5 a Turn the engine starting switch OFF for the preparations, and hold it in the ON
defective
(Wiper motor system) Between (9) and grounding, OFF Max. 3 V
Between (10) and Max. 3 V 20 – 30 V
grounding ON
(Constant cycle)
36 PC600-8
Electrical circuit diagram related to wiper motor (Single wiper specification)
PC600-8 37
Failure
• Wiper and window washer do not work. (4) Window washer does not operate.
information
Relative
—
information

1 Fuse No. 4 defective If fuse is broken, the circuit probably has grounding fault, etc. (See cause 4.)
Washer motor defective
2 (Internal disconnection or M06 (male) Resistance value
grounding fault) Between (1) and (2) 5 – 20 z

Presumed cause and
harness
Wiring harness from F01-4 outlet to J02 and M06 Resistance
(female) (1) value
tor) Wiring harness from M06 (female) (2) and CM01 Resistance
Max. 1 z
(female) (3) value
harness
4 Between wiring harness from F01-4 outlet to J04 and
circuit) M06 (female) (1), or F01-4 outlet to D04 (female) (2), Min. 1 Mz
value
and to other relative circuits and grounding
Machine monitor CM01 Washer switch Voltage
5
defective
OFF 20 – 30 V
ON Max. 1 V
38 PC600-8
Electrical circuit diagram related to window washer motor
PC600-8 39
E-18 "Boom Raise" is not correctly displayed in monitoring function

"Boom Raise" is not correctly displayed in the moni-
Failure • "Boom Raise" is not correctly displayed in moni-
toring function (special function) on the machine
information toring function
monitor.
Relative
—
information

Boom Raise PPC pres-
sure switch defective R.H. work equipment
1 P06 (male) Resistance value
(Internal disconnection or control lever
short-circuiting) NEUTRAL Min. 1 Mz
Between (2) and (1)
Boom RAISE Max. 1 z
harness

(female) (2) value
Presumed cause and

tor) Resistance
value
3
circuit) Min. 1 Mz
Voltage Max. 1 V
a Turn the engine starting switch OFF for the preparations, and start the engine
R.H. work equipment
control lever
Between (10) and NEUTRAL 20 – 30 V
grounding Boom RAISE Max. 1 V
Electrical circuit diagram related to boom Raise PPC pressure switch
40 PC600-8
E-19 "Boom Lower" is not correctly displayed in monitoring function

"Boom Lower" is not correctly displayed in the moni-
Failure • "Boom Lower" is not correctly displayed in moni-
toring function (special function) on the machine
monitor.
Relative
—
information

Boom Lower PPC pres-
Between (2) and (1)
Boom LOWER Max. 1 z
harness

(female) (2) value
Presumed cause and

tor) Resistance
value
3
circuit) Min. 1 Mz
Voltage Max. 1 V
R.H. work equipment
control lever
grounding Boom LOWER Max. 1 V
Electrical circuit diagram related to boom Lower PPC pressure switch
PC600-8 41
E-20 "Arm IN" is not correctly displayed in monitoring function

Failure • "Arm IN" is not correctly displayed in monitoring "Arm IN" is not correctly displayed in the monitoring
information function function (special function) on the machine monitor.
Relative
—
information

Arm IN PPC pressure
switch defective L.H. work equipment
Between (2) and (1)
Arm IN Max. 1 z
harness

(female) (2) value
Presumed cause and

tor) Resistance
value
3
circuit) Min. 1 Mz
Voltage Max. 1 V
L.H. work equipment
control lever
Between (30) and ground- NEUTRAL 20 – 30 V
ing Arm IN Max. 1 V
Electrical circuit diagram related to arm IN PPC pressure switch
42 PC600-8
E-21 "Arm OUT" is not correctly displayed in monitoring function

Failure • "Arm OUT" is not correctly displayed in monitor- "Arm OUT" is not correctly displayed in the monitoring
information ing function function (special function) on the machine monitor.
Relative
—
information

Arm OUT PPC pressure
switch defective L.H. work equipment
(Internal disconnection control lever
and short-circuiting) NEUTRAL Min. 1 Mz
Between (2) and (1)
Arm OUT Max. 1 z
harness

(female) (2) value
Presumed cause and

tor) Resistance
value
3
circuit) Min. 1 Mz
Voltage Max. 1 V
L.H. work equipment
control lever
grounding Arm OUT Max. 1 V
Electrical circuit diagram related to arm OUT PPC pressure switch
PC600-8 43
E-22 "Bucket CURL" is not correctly displayed in monitoring function

"Bucket CURL" is not correctly displayed in the mon-
Failure • "Bucket CURL" is not correctly displayed in
itoring function (special function) on the machine
information monitoring function
monitor.
Relative
—
information

Bucket CURL PPC pres-
Between (2) and (1)
Bucket CURL Max. 1 z
harness

(female) (2) value
Presumed cause and

tor) Wiring harness between P01 (female) (1) to J12 and Resistance
Max. 1 z
grounding value
3
circuit) Min. 1 Mz
P01 (female) (2) and grounding value
harness Between wiring harness between CP03 (female) (9) and
Voltage Max. 1 V
P01 (female) (2) and grounding
R.H. work equipment
control lever
NEUTRAL 20 – 30 V
Bucket CURL Max. 1 V
Electrical circuit diagram related to bucket CURL PPC pressure switch
44 PC600-8
E-23 "Bucket DUMP" is not correctly displayed in monitoring function

"Bucket DUMP" is not correctly displayed in the mon-
Failure "Bucket DUMP" is not correctly displayed in moni-
itoring function (special function) on the machine
monitor.
Relative
—
information

Bucket DUMP PPC pres-
Between (2) and (1)
Bucket DUMP Max. 1 z
harness

(female) (2) value
Presumed cause and

tor) Resistance
value
3
circuit) Min. 1 Mz
Voltage Max. 1 V
R.H. work equipment
control lever
grounding Bucket DUMP Max. 1 V
Electrical circuit diagram related to bucket DUMP PPC pressure switch
PC600-8 45
E-24 "Swing" is not correctly displayed in monitoring function

Failure • "Swing" is not correctly displayed in monitoring "Swing" is not correctly displayed in the monitoring
information function function (special function) on the machine monitor.
Relative
—
information

Swing PPC pressure
switch defective R.H. work equipment
Between (2) and (1)
Swing operated Max. 1 z
harness

(female) (2) value
Presumed cause and

tor) Resistance
value
3
(Contact with grounding Wiring harness between CP03 (female) (29) and P03 Resistance
(female) (2) and grounding value
harness Wiring harness between CP03 (female) (29) and P03
Voltage Max. 1 V
(female) (2) and grounding
R.H. work equipment
control lever
grounding Swing operated Max. 1 V
46 PC600-8
Electrical circuit diagram related to swing PPC pressure switch
PC600-8 47
E-25 "Travel" is not correctly displayed in monitoring function

Failure • "Travel" is not correctly displayed in the monitor- "Travel" is not correctly displayed in the monitoring
information ing function. function (special function) of the machine monitor.
Relative
—
information

Travel PPC pressure running during the troubleshooting.
switch defective P09 (male) Travel lever Resistance value
1
short-circuiting) Neutral Min. 1 Mz
Between (2) and (1)
Operated Max. 1 z
harness

(female) (2) value
Presumed cause and

tor) Resistance
value
3
circuit) Min. 1 Mz
Voltage Max. 1 V
Between (39) and Neutral 20 – 30 V
grounding Operated Max. 1 V
48 PC600-8
Electrical circuit diagram related to travel PPC pressure switch
PC600-8 49
E-26 Air conditioner does not work

Failure
• Air conditioner does not work.
information
Relative
—
information

When fuse is blown, there is a big possibility that grounding fault occurred in the cir-
1 Fuse No. 11 defective
cuit. (See Cause 3.)
harness
Wiring harness between F01-11 outlet and M26 (male) Resistance

(5) value
Presumed cause and

tor) Resistance
value
3
(Contact with grounding Between wiring harness between F01-11 outlet and M26
(GND) circuit) Voltage Min. 1 Mz
(male) (5) and grounding
Air conditioner unit M26 Voltage
4
defective Between (5) and (8) 20 – 30 V
If the above voltages are normal and the air conditioner does not operate, the air con-
ditioner unit is defective.
Electrical circuit diagram related to air conditioner
50 PC600-8
PC600-8 51
E-27 Step light does not light up or go off

Failure (1) When switch is pressed, light does not light up for
• Step light does not light up or go off
information 1 minute.
Relative
—
information

1 Defective fuse No. 20 If fuse is broken, circuit probably has ground fault (See cause 6).
2 Defective step light Step light may be defective. Check bulb directly for breakage.
starting switch ON.
Defective step light
3 switch (Internal discon- S13 (male) Step light switch Resistance
nection) Released Min. 1 Mz
Between (1) – (2)
Pressed Max. 1 z
Defective step light relay starting switch ON.
4
(Internal defect) When step light relay is replaced with another relay, if condition
R09
becomes normal, step light relay is defective.
Presumed cause and
starting switch ON.

Wiring harness between F01-20 outlet – J06 (female)
Resistance Max. 1 z
(19)
Wiring harness between J06 (female) (20) – S13
Resistance Max. 1 z
(female) (2)
Wiring harness between J06 (female) (17), (18) – R09
Resistance Max. 1 z
(female) (1), (3)
Disconnection in wiring Wiring harness between S13 (female) (1) – J06 (female)
Resistance Max. 1 z
harness (Disconnection (3)
5
in wiring or defective con- Wiring harness between J06 (female) (2) – CP01
(female) (24)
Wiring harness between J06 (female) (1) – D03 – J07
Resistance Max. 1 z
(female) (11), (12) – CP03 (female) (14), (24)
Wiring harness between R09 (female) (2) – CP02
Resistance Max. 1 z
(female) (19)
Wiring harness between R09 (female) (5) – L06
Resistance Max. 1 z
(female) (1)
Wiring harness between L06 (female) (2) – chassis
Resistance Max. 1 z
ground
52 PC600-8

starting switch ON.
Wiring harness between F01-20 outlet – J06 – S13
(female) (2), or R09 (female) (2), (3) – chassis ground
Ground fault in wiring Wiring harness between S13 (female) (1) – J06 – CP01
6 harness (Contact with (female) (24), or D03 – J07 – CP03 (female) (14), (24) – Resistance Min. 1 Mz
GND circuit) chassis ground
Wiring harness between R09 (female) (5) – H02 – L06

Presumed cause and
Wiring harness between R09 (female) (2) – CP02
starting switch ON.
Defective pump controller
(Step light switch input CP01 Step light switch Voltage
system) Between (24) – Released Max. 1 V
chassis ground Pressed 20 – 30 V
7
starting switch ON.
(Step light relay output CP02 Step light switch Voltage
system) Between (19) – Released Max. 1 V
chassis ground Pressed 20 – 30 V (60 seconds)
PC600-8 53
Failure
• Step light does not light up or go off (2) While switch is not pressed, light lights up.
information
Relative
—
information

starting switch ON.
Defective step light S13 (male) Step light switch Resistance
1
(Internal short circuit)
Released Min. 1 Mz
Between (1) – (2)
Pressed Max. 1 z
Defective step light relay starting switch ON.
2
(Internal defect) When step light relay is replaced with another relay, if condition
R09
becomes normal, step light relay is defective.
Presumed cause and
troubleshooting.
Hot short (Short circuit Wiring harness between S13 (female) (1) – J06 – CP01
3 with 24 V circuit) in wiring (female) (24), or D03 – J07 – CP03 (female) (14), (24) – Voltage Max. 1 V
harness chassis ground
Wiring harness between CP02 (female) (19) – R09
Voltage Max. 1 V
starting switch ON.
(Step light switch input CP01 Step light switch Voltage
system) Between (24) – chassis Released Max. 1 V
ground Pressed 20 – 30 V
4
starting switch ON.
(Step light relay output CP02 Step light switch Voltage
system) Between (19) – chassis Released Max. 1 V
ground Pressed 20 – 30 V (60 seconds)
54 PC600-8
Electrical circuit diagram related to step light
PC600-8 55
E-28 Electric grease gun does not operate

Failure
• Electric grease gun does not operate.
information
Relative
—
information

Circuit breaker No. 3 If the circuit breaker is turned OFF, there is a big possibility that grounding fault
1
defective occurred in the circuit (See cause 3).

Presumed cause and
harness
Wiring harness between B01 (female) (F) and M16 Resistance
(male) (1) value
tor) Resistance
value
3
(Contact with grounding Wiring harness between B01 (female) (F) and M16 Resistance
circuit) Min. 1 Mz
(male) (1) and grounding value
If causes 1 – 3 are not detected, the grease pump may be defective. (Since trouble
4 Grease pump defective
is in the grease pump, troubleshooting cannot be carried out.)
Electrical circuit diagram related to electric grease gun
56 PC600-8
PC600-8 57
E-29 Travel alarm does not sound or does not stop sounding
(1) The alarm does not sound while the machine is trav-
Failure • Travel alarm does not sound or does not stop
eling.
information sounding.
(2) The alarm sounds while the machine is stopped.
Relative
—
information

1 Travel signal defective 01900 Lever operated: ON
Travel
If the display on the monitor panel is abnormal, carry out troubleshooting in " is
not displayed normally in monitoring function".
M14 (female) Travel lever Voltage
Travel alarm defective
2 Neutral Max. 1 V
(Internal defective) Between (1) and (2)
Presumed cause and
If the above voltages are normal and the travel alarm does not sound, the travel
alarm is defective.
harness
Wiring harness between CP03 (female) (8) and M14 Resistance
(female) (1) value
tor) Resistance
Wiring harness between M14 (female) (2) and grounding Max. 1 z
value
harness Between wiring harness between CP03 (female) (8) and
Voltage Max. 1 V
M14 (female) (1) and grounding
Neutral Max. 1 V
58 PC600-8
Electrical circuit diagram related to travel alarm
PC600-8 59
©2006 KOMATSU
All Rights Reserved
60
UEN00452-00
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 K50001 and up

40 Troubleshooting
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) ......................................................................... 3

Before troubleshooting H-mode...................................................................................................................... 3
Information in Troubleshooting Table.............................................................................................................. 8
H-1 Speed or power of all work equipment, travel, and swing is low............................................................ 10
H-2 Engine speed lowers remarkably or engine stalls.................................................................................. 12
H-3 All work equipment, travel, and swing systems do not work.................................................................. 14
H-4 Abnormal sound is heard from around pump ........................................................................................ 16
H-5 Auto-decelerator is not reset.................................................................................................................. 17
H-6 Boom speed or power is low.................................................................................................................. 18
H-7 Arm speed or power is low .................................................................................................................... 20
H-8 Bucket speed or power is low ................................................................................................................ 21
H-9 Boom does not move ............................................................................................................................. 22
H-10 Arm does not move.............................................................................................................................. 22
H-11 Bucket does not move.......................................................................................................................... 22
H-12 Hydraulic drift of work equipment is large ............................................................................................ 23
H-13 Time lag of work equipment is large .................................................................................................... 24
H-14 Power max. function does not operate or stop .................................................................................... 25
H-15 Machine push-up function does not operate or stop............................................................................ 25
H-16 When arm and boom, bucket are operated simultaneously, boom, bucket speed is low .................... 26
PC600-8 1
H-17 When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel
speed is low............................................................................................................................................. 26
H-18 When arm and swing are operated simultaneously, swing speed is low ............................................. 27
H-19 Machine deviates in one direction........................................................................................................ 28
H-20 Machine deviates largely at start ......................................................................................................... 30
H-21 Travel deviation is large during compound operation .......................................................................... 31
H-22 Travel speed or power is low ............................................................................................................... 32
H-23 Machine does not travel (only one track) ............................................................................................. 33
H-24 Travel speed does not change............................................................................................................. 34
H-25 Upper structure does not swing ........................................................................................................... 35
H-26 Swing speed or acceleration is low ...................................................................................................... 36
H-27 Upper structure overruns excessively when it stops swinging ............................................................. 37
H-28 Large shock is made when upper structure stops swinging ................................................................ 38
H-29 Large abnormal sound is made when upper structure stops swinging ................................................ 39
H-30 Hydraulic drift of swing is large ............................................................................................................ 40
2 PC600-8
Troubleshooting of hydraulic and mechanical sys-

tem (H-mode)
Before troubleshooting H-mode
PC600-8 3
1. Combination and operation of hydraulic 2. Finding cause of trouble that "work equip-
pumps ment speed is low and machine deviates to
• For the work equipment, travel, and swing right"
circuits, 2 tandem pumps (4 pump units) of • The possible causes of this trouble are as
the No. 1 pump (HPV95+95) and the No. 2 follows:
pump (HPV95+95) are used. 1) The main relief valve of the right side 5-
• The oil from the No. 1 front pump and that spool valve is defective.
from the No. 2 front pump merge together 2) The jet sensor of the right side 5-spool
and flow in the right side 5-spool valve. The valve is defective.
oil from the No. 1 rear pump and that from 3) The CO, NC valve of the No. 1 front
the No. 2 rear pump merge together and flow pump is defective.
in the left side 4-spool valve. 4) The servo valve of the No. 1 front pump
• The TVC valve installed on the No. 1 rear is defective.
pump carries out the TVC control of the No. 5) The No. 1 front pump is defective.
1 pump and No. 2 pump similarly. 6) The servo valve of the No. 2 front pump
• The CO, NC valve installed on the No. 1 front is defective.
pump and the jet sensor installed to the right 7) The No. 2 front pump is defective.
side 5-spool valve carry out the CO, NC con- • Whether the main relief valve, jet sensor,
trol of the No. 1 front pump and No. 2 front and CO, NC valve are good or not can be
pump similarly. judged by measuring the relief pressure, dif-
• The CO, NC valve installed on the No. 1 rear ferential pressure, and output pressure re-
pump and the jet sensor installed to the left spectively.
side 4-spool valve carry out the CO, NC con- • Since the oil from the No. 1 front pump and
trol of the No. 1 rear pump and No. 2 rear that from the No. 2 front pump merge togeth-
pump similarly. er as explained in 1 above, exchange the
outlet hoses of the No. 2 front and rear
pumps and check the phenomenon of the
machine to find out a defective system in the
servo valves and pump units of the No. 1 and
No. 2 front pumps.
1) If the machine still deviates to the right
(If deviation does not change), the No. 1
front pump system is defective.
2) If the machine deviates to the left (If
deviation changes), the No. 2 front
pump system is defective.
3) If the travel speed lowers, the jet sensor
or the CO, NC valve is defective (when
the right and left relief pressures are
normal).
• To judge the condition of the servo valve and
pump unit, remove the servo valve and test it
or measure the stroke of the servo piston.
a Actually, judge the condition according "4.
Judgment matrix for trouble that work equip-
ment speed is low and machine deviates".
4 PC600-8
3. Finding cause of trouble that "work equip- 4. Judgment matrix for trouble that work equip-
ment speed is low and machine deviates to ment speed is low and machine deviates (on
left" the next page)
• The possible causes of this trouble are as a Carry out diagnosis in order from the top line
follows: and judge the factor having the most black
1) The main relief valve of the left side 4- points (q) to be the cause of the trouble.
spool valve is defective. 1) To judge the servo valve, remove it and test
2) The jet sensor of the left side 4-spool it or measure the stroke of the servo piston.
valve is defective. a Perform the test on the servo piston unit
3) The CO, NC valve of the No. 1 rear in the specified maintenance shop.
pump is defective. 2) If the speed lowers extremely and the pump
4) The servo valve of the No. 1 rear pump seems to be abnormal, check the line filter
is defective. too.
5) The No. 1 rear pump is defective. 3) If the speed lowers little but cannot be set to
6) The servo valve of the No. 2 rear pump the normal level by adjusting each device,
is defective. check the line filter too.
7) The No. 2 rear pump is defective. 4) To check the operation of the servo piston,
• Whether the main relief valve, jet sensor, remove the caps from both sides of it and
and CO, NC valve are good or not can be move the servo piston with the hand.
judged by measuring the relief pressure, dif-
ferential pressure, and output pressure re-
spectively.
• Since the oil from the No. 1 rear pump and
that from the No. 2 rear pump merge togeth-
er as explained in 1 above, exchange the
outlet hoses of the No. 2 front and rear
pumps and check the phenomenon of the
machine to find out a defective system in the
servo valves and pump units of the No. 1 and
No. 2 rear pumps.
1) If the machine still deviates to the left (If
deviation does not change), the No. 1
rear pump system is defective.
2) If the machine deviates to the right (If
deviation changes), the No. 2 rear pump
system is defective.
3) If the travel speed lowers, the jet sensor
or the CO, NC valve is defective (when
the right and left relief pressures are
normal).
• To judge the condition of the servo valve and
pump unit, remove the servo valve and test it
or measure the stroke of the servo piston.
a Actually, judge the condition according "4.
Judgment matrix for trouble that work equip-
ment speed is low and machine deviates".
PC600-8 5
Causes
Left Right
No. 1 pump No. 2 pump 4-spool 5-spool
valve valve
Front Rear
Front pump Rear pump
pump pump
Main relief valve defective
Main relief valve defective

CO•NC valve defective
CO•NC valve defective

Servo valve defective
Jet sensor defective
Jet sensor defective

Pump unit defective
Pump unit defective
Pump unit defective
Pump unit defective
R.H. travel motor

L.H. travel motor
Remedy A: Adjust
Remedy X: Repair or replace
Remedy
A A A A A A
No.
X X X X X X X X X X X X X X X X
Diagnosis
Machine "deviates to right" and work equipment speed
1
and swing speed are low.
q q q q q q q
Machine "deviates to right" and single swing speed is
2
particularly low.
q q q q q q
Machine "deviates to right" and single swing speed is
3
normal.
q
4 Travel relief pressure of front pump circuit is low. q
Machine "deviates to right"
Machine "deviates to right"

5
(Deviation does not change).
q q q
When result of 4 is nor-
mal, exchange front and Machine "deviates to left"
6
rear outlet hoses of No. 2 (Deviation changes).
q q
pump. Speed of both travel motors
7
is low.
q q
When phenomenon of 5 occurs, servo valve of No. 1
8
front pump is normal.
q
9
front pump is normal.
q
When phenomenon of 7 occurs, jet sensor differential
10
pressure of right side 5-spool valve is abnormal.
q
When result of 10 is normal, No. 1 front NC valve output
11
pressure is abnormal.
q
Machine "deviates to left" and work equipment speed is
12
low.
q q q q q q q
Machine "deviates to left" and bucket dump speed is
13
particularly low.
q q q q q q
Machine "deviates to left" and bucket dump speed is
14
normal.
q
15 Travel relief pressure of rear pump circuit is low. q
Machine "deviates to left"
Machine "deviates to left"

16 q q q
When result of 15 is nor- (Deviation does not change).
mal, exchange front and Machine "deviates to right"
17
rear outlet hoses of No. 2 (Deviation changes).
q q
pump. Speed of both travel motors
18
is low.
q
19
rear pump is normal.
q
20
rear pump is normal.
q
When phenomenon of 18 occurs, jet sensor differential
21
pressure of left side 4-spool valve is abnormal.
q
When result of 18 is normal, No. 1 front NC valve output
22
pressure is abnormal.
q
6 PC600-8
How to exchange outlet hoses of No. 2 pump and hydraulic circuit diagram after they are exchanged
PC600-8 7
Information in Troubleshooting Table
a Tables and related circuit diagrams concerning troubleshooting contains the following information. Please
understand the contents sufficiently before carrying out troubleshooting.
Failure
Phenomena on machine
Phenomenon
Related
Information concerning to failure or troubleshooting.
Information
1
Presumed cause and
2
Causes for presumed
failure
<Contents>
(The attached No. for fil-
• Standard values for judgement of possible causes.
ing and reference pur-
• Remarks for judgement
pose only. It does not
stand for any priority)
3
8 PC600-8
PC600-8 9
H-1 Speed or power of all work equipment, travel, and swing is low
Failure
• Speed or power of all work equipment, travel, and swing is low
information
• Measure the speed of the work equipment, travel, and swing speed and check that all of them are slow
(or their power is low).
• Check that abnormal sound is not heard from around the pump.
Relative
(If abnormal sound is heard, carry out the related troubleshooting.)
information
• Check that the machine does not deviate.
(If the machine deviates, carry out the related troubleshooting.)
• Carry out all the troubleshooting in working mode P.

a Run the engine at high idle during troubleshooting.
Power max. switch and right work
Engine speed
equipment control lever
1 Engine unit defective
Power max. switch OFF +
Above 1,780 rpm
Boom RAISE relief
Power max. switch ON + Boom RAISE relief Above 1,730 rpm
PTO defective internally a Keep the engine stopped for the preparations and troubleshooting.
2 (Control pump drive Disconnect the control pump outlet hose and rotate the crankshaft. If oil flows out of
system) the pump outlet, PTO is normal.
Control pump defective Control pump may be defective internally. Check inside of pilot filter for metal dust,
3
internally etc.
a Keep the engine stopped for the preparations, and run it at high idle during
troubleshooting.
Control levers Control relief pressure

Presumed cause and
Wrong adjustment or 3.14

+0.29
MPa
0
4 malfunction of control All levers in neutral +3
relief valve {32 0 kg/cm2}
If the oil pressure is still abnormal after adjustment, check cause 5. If cause 5 is not
detected, the control relief valve operation may be defective. Check the control relief
valve directly.
a Stop the engine and block (1) – (7) in Fig. 1 in order. Run the engine at high idle
and check.
Leakage in control Control levers Control relief pressure
5
system devices +0.29
3.14 0 MPa
All levers in neutral +3
{32 0 kg/cm2}
troubleshooting.
Right work equipment control lever Main relief pressure

Wrong adjustment or +1.47
6 malfunction of main relief 31.87 –0.98 MPa
valve Boom RAISE relief +15
{325 –10 kg/cm2}
If the oil pressure is still abnormal after adjustment, the main relief valve (on the low-
pressure set side and high-pressure set side) may be defective. Check the main
relief valve directly.
10 PC600-8

troubleshooting (Start troubleshooting after checking that causes 4 and 6 are not
detected).
Right work equipment control lever TVC valve output pressure
Min. 1.76 MPa

Wrong adjustment or All levers in neutral
Presumed cause and
7 {Min. 18 kg/cm 2}
malfunction of TVC valve
+0.20
1.05 –0.53 MPa
Boom RAISE relief
+2.0
{10.7 –5.4 kg/cm2}
If the oil pressure is still abnormal after adjustment, the TVC valve may be defective.
Check the TVC valve directly.
troubleshooting.
Malfunction of CO Swing lock switch Solenoid valve outlet pressure
8
cancel solenoid valve Min. 2.74 MPa
ON
{Min. 28 kg/cm 2}
OFF 0 MPa {0 kg/cm2}
Fig. 1: Control system devices
PC600-8 11
H-2 Engine speed lowers remarkably or engine stalls

Failure
• Engine speed lowers remarkably or engine stalls
Phenomenon
Related
Information

a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
R.H. work equipment control lever TVC valve output pressure
Min. 1.76 MPa
Defective adjustment or All control levers in neutral
1 {Min. 18 kg/cm2}
malfunction of TVC valve
+0.20
1.05 –0.53 MPa

Boom relieved in RAISE position
Presumed cause and
+2.0
{10.7 –5.4 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the TVC valve may have a
malfunction. Check the TVC valve directly.
high idle. (Check cause 1 and confirm that the result is normal before
troubleshooting.)
Defective adjustment or R.H. work equipment control lever CO, NC valve output pressure
2 malfunction of CO, NC +0.20
valve 1.05 –0.53 MPa
Boom relieved in RAISE position
+2.0
{10.7 –5.4 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the CO, NC valve may have
a malfunction. Check the CO, NC valve directly.
If the results of check of causes 1 and 2 are normal, the engine may be defective.
3 Defective engine
Check the engine
12 PC600-8
PC600-8 13
H-3 All work equipment, travel, and swing systems do not work
Failure
• All work equipment, travel, and swing systems do not work
information
Relative
information

1 (Main pump drive Disconnect the main pump oil pressure pickup coupler and rotate the crankshaft. If
system) oil flows out of the pump outlet, PTO is normal.
2 (Control pump drive Disconnect the control pump outlet hose and rotate the crankshaft. If oil flows out of
system) the pump outlet, PTO is normal.
Control pump defective Control pump may be defective internally. Check inside of pilot filter for metal dust,
3
internally etc.
troubleshooting.
Control levers Control relief pressure

Presumed cause and
Wrong adjustment or 3.14

+0.29
MPa
0
4 malfunction of control All levers in neutral +3
relief valve {32 0 kg/cm2}
If the oil pressure is still abnormal after adjustment, check cause 5. If cause 5 is not
detected, the control relief valve operation may be defective. Check the control relief
valve directly.
a Stop the engine and block (1) – (9) in Fig. 1 in order. Run the engine at high idle
and check.
Leakage in control Control levers Control relief pressure
5
system devices +0.29
3.14 0 MPa
All levers in neutral +3
{32 0 kg/cm2}
troubleshooting.
Malfunction of PPC lock Work equipment lock lever Solenoid valve outlet pressure
6
solenoid valve Min. 2.74 MPa
FREE
{28 kg/cm2}
LOCK 0 MPa {0 kg/cm2}
14 PC600-8
Fig. 1: Control system devices
PC600-8 15
H-4 Abnormal sound is heard from around pump

Failure
• Abnormal sound is heard from around pump
Phenomenon
Related
—
Information

Presumed cause and standard
1 Low hydraulic oil level Since the hydraulic oil level may be low, check it directly.
Since a piping clamp between the hydraulic tank and hydraulic pump may be loos-
value in normalcy
2 Loosened piping clamp

ened, check it directly.
Clogged hydraulic tank
3 Since the hydraulic tank strainer may be clogged, check it directly.
strainer
Internal defect of hydrau-
4 Since the hydraulic pump may have a defect in it, check it directly.
lic pump
If a cause cannot be found by troubleshooting, operate the machine as it is for a
5 Observation of condition
while and observe the condition for change.
16 PC600-8
H-5 Auto-decelerator is not reset

Failure
• Auto-decelerator is not reset (1) When machine swings, auto-decelerator is not reset.
information
• The signal pressure of the swing PPC circuit is input through the arm•swing PPC shuttle valve (swing
Relative
side) to the swing PPC pressure switch.
information
• Carry out all troubleshooting in working mode P.

Presumed cause and
a Stop the engine for the preparations, and keep it running at high idle during the
troubleshooting.
L.H. work equipment control lever Shuttle valve outlet pressure
Malfunction of arm, swing
1 PPC shuttle valve 0 MPa
Neutral
(swing side) {0 kg/cm2}
Min. 2.74 MPa

Swing left • right stroke end
{Min. 28 kg/cm 2}
Failure
• Auto-decelerator is not reset (2) When machine travels, auto-decelerator is not reset.
information
• The signal pressure of the travel PPC circuit is input through the travel PPC shuttle valve (in the travel
Relative
PPC valve) to the travel PPC pressure switch.
information

Presumed cause and
a Stop the engine for the preparations (measure at the travel PPC pressure switch),
and keep it running at high idle during the troubleshooting.
Travel lever PPC valve output pressure
Malfunction of travel PPC
1 valve 0 MPa
All levers in neutral
(internal shuttle valve) {0 kg/cm2}
Min. 2.74 MPa

R.H. and L.H. forward-reverse stroke end
{Min. 28 kg/cm 2}
PC600-8 17
H-6 Boom speed or power is low

Failure
• Boom speed or power is low (1) Boom speed or power is low in normal mode.
information
• The normal mode means the condition that machine push-up switch are turned OFF.
• Check that other work equipment, travel system, and swing system are normal. (If any of them is
Relative abnormal, carry out troubleshooting related to it.)
information • Check that the machine does not deviate during travel. (If the machine deviates, carry out trouble-
shooting related to travel deviation.)

troubleshooting.
Malfunction of right PPC
1 R.H. work equipment control lever PPC valve output pressure
valve (boom circuit)
Min. 2.74 MPa
Boom RAISE, LOWER full stroke
{Min. 28 kg/cm2}
Malfunction of boom
2 The spool of the boom control valve (Lo, Hi) may be malfunctioning. Check it directly.
control valve (spool)

Presumed cause and
Malfunction of boom con- The main unit of the boom control valve (Lo, Hi) may be malfunctioning. Check it
3
trol valve (main unit) directly.
The safety & suction valve of the boom lock valve may be malfunctioning. Check it
Malfunction of boom lock
directly. (The safety & suction valve may be checked by exchanging it with a valve of
4 valve
another work equipment circuit. After finishing check, however, be sure to return the
(safety & suction valve)
safety-suction valve since its set pressure and structure are different from others.)
The safety & suction valve of the boom regeneration valve may be malfunctioning.
Malfunction of boom Check it directly. (When checking the safety & suction valve by exchanging it with a
5 regeneration valve valve of another work equipment circuit, stop the hose of the machine push-up sole-
(safety & suction valve) noid securely. After finishing check, be sure to return the safety & suction valve since
its set pressure and structure are different from others.)
Defective seal of boom troubleshooting.
6
cylinder R.H. work equipment control lever Leakage from cylinder
Boom RAISE relief Max. 20 cc/min
18 PC600-8
Failure
• Boom speed or power is low (2) Boom raise speed or power is low in L-mode.
information
• Check that the other work equipment, travel, and swing are normal. (If any of them is abnormal, carry
Relative out troubleshooting related to it.)
information • Check that the machine does not deviate. (If it deviates, carry out troubleshooting related to deviation.)

troubleshooting.
Malfunction of CO R.H. work equipment control lever Solenoid valve outlet pressure
1
cancel solenoid valve Neutral 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Single boom RAISE operation
{Min. 28 kg/cm 2}
a Keep the engine stopped for the preparations, and run it at high idling during
Presumed cause and
troubleshooting.
Malfunction of 2-stage R.H. work equipment control lever Solenoid valve outlet pressure
2
relief solenoid valve Neutral 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Single boom RAISE operation
{Min. 28 kg/cm 2}
a Keep the engine stopped for the preparations, and run it at high idling during
troubleshooting.
R.H. work equipment control lever Main relief pressure
Wrong adjustment or +1.5
3 malfunction of main relief 37.2 –2.0 MPa
valve Single boom RAISE operation +15
{380 –20 kg/cm2}
If the main relief valve is still abnormal after adjustment, its operation (on the high
pressure set side) may be defective. Check it directly.
Failure (3) Boom lower speed or power is low in the machine

• Boom speed or power is low
information push-up mode.
• The machine push-up mode is the state that the machine push-up switch is turned ON.
• Check that the other work equipment, travel, and swing are normal. (If any of them is abnormal, carry
Relative
out troubleshooting related to it.)
information
• Check that the machine does not deviate. (If it deviates, carry out troubleshooting related to deviation.)

Presumed cause and
troubleshooting.
Malfunction of machine Machine push-up switch Solenoid valve outlet pressure
1
push-up solenoid valve Min. 2.74 MPa
OFF
{Min. 28 kg/cm 2}
ON 0 MPa {0 kg/cm2}
Malfunction of boom
The safety & suction valve of the boom regeneration valve (on the high pressure set
2 regeneration valve
side) may malfunction. Check it directly.
PC600-8 19
H-7 Arm speed or power is low

Failure
• Arm speed or power is low
Phenomenon
• Check that the speeds of the other work equipment, travel, and swing are normal.
(If they are abnormal, carry out the related troubleshooting.)
Related
Information

high idle.
Malfunction of left PPC
1 L.H. work equipment control lever PPC valve output pressure
valve (arm circuit)
Arm IN, OUT Min. 2.74 MPa
full stroke {Min. 28 kg/cm 2}

Presumed cause and
Malfunction of arm Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it
2
control valve (spool) directly.
The safety-suction valve of the arm control valve (Lo) may malfunction. Check it
Malfunction of arm
directly. (After checking the safety-suction valve by exchanging it with a valve of
3 control valve
another work equipment circuit, be sure to return it since its set pressure is different
from others.)
Defective arm control Since the body of the arm control valve (Lo, Hi) may have a malfunction, check it
4
valve (body) directly.
Defective seal of arm high idle.
5
cylinder L.H. work equipment control lever Leakage from cylinder
Relieved in arm CURL position Max. 20 cc/min
20 PC600-8
H-8 Bucket speed or power is low

Failure
• Bucket speed or power is low
Phenomenon
• Check that the speeds of the other work equipment, travel, and swing are normal.
Related
Information

high idle.
valve (bucket circuit)
Bucket CURL, DUMP Min. 2.74 MPa
Presumed cause and
Malfunction of bucket Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it
2
Since the safety & suction valve of the bucket control valve (Lo, Hi) may have a mal-
Malfunction of bucket function, check it directly. (The safety & suction valve may be checked by replacing it
3 control valve with one of another work equipment circuit. After checking, however, be sure to
(safety & suction valve) return the safety & suction valve since its set pressure and structure are different
from the others.)
Defective bucket control Since the body of the bucket control valve (Lo, Hi) may have a malfunction, check it
4
valve (body) directly.
Defective seal of bucket high idle.
5
Relieved in bucket CURL position Max. 20 cc/min
PC600-8 21
H-9 Boom does not move

Failure
• Boom does not move
Phenomenon
• Check that operations of the other work equipment, travel, and swing are normal.
Related
Information

high idle.
value in normalcy

1 valve R.H. work equipment control lever PPC valve output pressure
(boom circuit) Boom RAISE, LOWER Min. 2.74 MPa
Malfunction of boom Since the spool of the boom control valve (Lo, Hi) may have a malfunction, check it
2
H-10 Arm does not move

Failure
• Arm does not move
Phenomenon
Related
Information

high idle.
value in normalcy

valve (arm circuit)
Arm IN, OUT Min. 2.74 MPa
Malfunction of arm Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it
2
H-11 Bucket does not move

Failure
• Bucket does not move
Phenomenon
Related
Information

high idle.
value in normalcy

valve (bucket circuit)
Bucket CURL, DUMP Min. 2.74 MPa
Malfunction of bucket Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it
2
22 PC600-8
H-12 Hydraulic drift of work equipment is large

Failure
• Hydraulic drift of work equipment is large (1) Hydraulic drift of boom is large
Phenomenon
Related
—
Information


1 Since the poppet of the boom lock valve may have a malfunction, check it directly.
valve (poppet)
value in normalcy

Since the safety & suction valve of the boom lock valve may have a malfunction,
2 valve(safety & suction
check it directly.
valve)
Defective seal of boom high idle.
3
Relieved in boom RAISE position Max. 20 cc/min
Failure
• Hydraulic drift of work equipment is large (2) Hydraulic drift of arm is large
Phenomenon
Related
—
Information

Defective seal of arm Since the spool of the arm control valve (Lo) may have a malfunction, check it
1
Since the safety & suction valve (head side) of the arm control valve (Lo) may have a
value in normalcy
Malfunction of arm malfunction, check it directly. (The safety & suction valve may be checked by replac-
2 control valve ing it with one of another work equipment circuit. After checking, however, be sure to
(safety & suction valve) return the safety & suction valve since its set pressure and structure are different
from the others.)
Defective seal of arm high idle.
3
cylinder L.H. work equipment control lever Leakage from cylinder
Relieved in arm IN position Max. 20 cc/min
Failure
• Hydraulic drift of work equipment is large (3) Hydraulic drift of bucket is large
Phenomenon
Related
—
Information

Defective seal of bucket Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it
1
Since the safety & suction valve (bottom side) of the bucket control valve (Lo, Hi)
value in normalcy
Malfunction of bucket may have a malfunction, check it directly. (The safety & suction valve may be
2 control valve checked by replacing it with one of another work equipment circuit. After checking,
(safety & suction valve) however, be sure to return the safety & suction valve since its set pressure and struc-
ture are different from the others.)
Defective seal of bucket high idle.
3
Relieved in bucket CURL position Max. 20 cc/min
PC600-8 23
H-13 Time lag of work equipment is large

Failure
• Time lag of work equipment is large (1) Time lag of boom is large
Phenomenon
Related
—
Information

Presumed Malfunction of boom
1 Since the boom regeneration valve may have a malfunction, check it directly.
cause and regeneration valve
standard value Malfunction of boom
in normalcy Since the suction valve (head side) of the boom control valve (Lo) may have a
2 control valve
malfunction, check it directly. (When checking by replacing with travel circuit.)
(suction valve)
Failure
• Time lag of work equipment is large (2) Time lag of arm is large
Phenomenon
Related
—
Information

Presumed Since the safety & suction valve (bottom side) of the arm control valve (Lo)
cause and Malfunction of arm may have a malfunction, check it directly. (The safety & suction valve may be
standard value 1 control valve (safety checked by replacing it with one of another work equipment circuit. After
in normalcy & suction valve) checking, however, be sure to return the safety & suction valve since its set
pressure and structure are different from the others.)
Failure
• Time lag of work equipment is large (3) Time lag of bucket is large
Phenomenon
Related
—
Information

Presumed Since the safety & suction valve (bottom side) of the bucket control valve (Lo,
cause and Malfunction of bucket Hi) may have a malfunction, check it directly. (The safety & suction valve may
standard value 1 control valve (safety be checked by replacing it with one of another work equipment circuit. After
in normalcy & suction valve) checking, however, be sure to return the safety & suction valve since its set
pressure and structure are different from the others.)
24 PC600-8
H-14 Power max. function does not operate or stop

Failure
• Power max. function does not operate or stop
Phenomenon
Related
Information

a Stop the engine for the preparations, and keep it running at high idle during
the troubleshooting.
Presumed Malfunction of Power max. switch Solenoid valve outlet pressure
cause and 1 2-stage relief 0 MPa
standard value solenoid valve OFF
{0 kg/cm2}
in normalcy
Min. 2.74 MPa
ON
{Min. 28 kg/cm2}
Malfunction of main
2 The main relief valve of the control valve may malfunction. Check it directly.
relief valve
H-15 Machine push-up function does not operate or stop
Failure
• Machine push-up function does not operate or stop
Phenomenon
Related
—
Information

cause and
standard value 1 Check by (3) in "H-6 Boom speed or power is low".
in normalcy
PC600-8 25
H-16 When arm and boom, bucket are operated simultaneously, boom, bucket speed is
low
Failure
• When arm and boom, bucket are operated simultaneously, boom, bucket speed is low
Phenomenon
• Check that all the operations are normal when performed singly. (If any of them is abnormal, carry out
Related
troubleshooting related to it.)
Information

Malfunction of boom, R.H. work equipment control lever Shuttle valve outlet pressure
Presumed
1 bucket PPC shuttle 0 MPa
cause and NEUTRAL
valve {0 kg/cm2}
standard value
in normalcy Min. 2.74 MPa
Boom or bucket full stroke
{Min. 28 kg/cm2}
Malfunction of control
2 valve The arm throttle valve of the control valve may malfunction. Check it directly.
(arm throttle valve)
H-17 When bucket and boom, arm, swing, travel are operated simultaneously, boom,
arm, swing, travel speed is low
Failure • When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel
Phenomenon speed is low
• Check that all the operations are normal when performed singly. (If any of them is abnormal, carry out
Related
Information

Presumed
L.H. and R.H. work equipment control
cause and Malfunction of bucket Solenoid valve outlet pressure
levers and travel lever
standard value 1 CURL Hi cancel
in normalcy solenoid valve Min. 2.35 MPa
Single operation of bucket CURL
{Min. 24 kg/cm2}
Operations other than single 0 MPa
operation of bucket CURL {0 kg/cm2}
26 PC600-8
H-18 When arm and swing are operated simultaneously, swing speed is low
Failure
• When arm and swing are operated simultaneously, swing speed is low
Phenomenon
• Check that both operations are normal when performed singly. (If either of them is abnormal, carry out
Related
Information

Malfunction of arm, L.H. work equipment control lever Shuttle valve outlet pressure
Presumed
1 swing PPC shuttle 0 MPa
cause and Neutral
valve (arm side) {0 kg/cm2}
standard value
in normalcy Min. 2.74 MPa
Arm IN or OUT full stroke
{Min. 28 kg/cm2}
The swing priority valve of the control valve may malfunction. Check it
2 valve (swing priority
directly.
valve)
PC600-8 27
H-19 Machine deviates in one direction

Failure (1) Machine deviates in the same direction, regardless
• Machine deviates in one direction
Phenomenon of its travel direction
Related • Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.)
Information • Carry out all the troubleshooting in working mode A.

Troubleshooting with Carry out troubleshooting by using the judgment matrix in BEFORE TROUBLE-
1
judgment matrix SHOOTING H MODE.
Wrong adjustment of
2 See TESTING AND ADJUSTING, Testing and adjusting travel deviation.
main pump
high idle.
Presumed cause and standard value in normalcy

3 Travel lever PPC valve output pressure
valve
FORWARD, REVERSE 2.74 MPa
Full stroke {28 kg/cm 2}
Malfunction of travel
4 Since the spool of the travel control valve may have a malfunction, check it directly.
Defective travel control
5 Since the body of the travel control valve may have a malfunction, check it directly.
valve (body)
high idle.
Defective seal of center Travel lever Leakage from swivel joint
6
swivel joint
Relieved on one side Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 2.
high idle.
7 Leakage in travel motor
Travel lever Leakage from travel motor
Relieved on one side Max. 20 l/min
8 Defective travel motor Since the travel motor may be defective, check it directly.
Internal defect of final Since the final drive may have a defect in it, check it directly. (The defect can be
9
drive judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.)
Fig. 2 Defective seals in center swivel joint and travel deviation directions
28 PC600-8
Failure (2) Machine deviates in different directions, depending

• Machine deviates in one direction
Phenomenon on its travel direction
Related • Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.)
Information • Carry out all the troubleshooting in working mode P.

high idle.
PPC valve
FORWARD, REVERSE 2.74 MPa
full stroke {28 kg/cm 2}
Presumed cause and
high idle.
Defective seal of center Travel lever Leakage from swivel joint
3
swivel joint
Relieved on one side Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 2.
high idle.
Low set pressure of Travel lever Travel relief pressure
4
travel motor safety valve
34.3 ± 1.47 MPa
Relieved on one side
{350 ± 15 kg/cm2}
Fig. 2 Defective seals in center swivel joint and travel deviation directions
PC600-8 29
H-20 Machine deviates largely at start

Failure (1) Machine deviates only when started with travel lever
• Machine deviates largely at start
Phenomenon at full stroke
• Check that the machine does not deviate during constant-speed travel.
Related
(If the machine deviates even during constant-speed travel, carry out the related troubleshooting.)
Information

Malfunction of main Since the servo valve of main pumps (No. 1 & No. 2) may have a malfunction, check
1
pump servo-valve it directly. (Test the servo valve unit or measure its stroke.)
value in normalcy
Defective seal of center troubleshooting.
3
swivel joint Travel lever Leakage from swivel joint
Either side relief Max. 100 cc/min
Internal defect of travel
4 Since the travel motor may have a defect in it, check it directly.
motor (body)
Failure (2) Machine deviates when started, regardless of travel

• Machine deviates largely at start
Phenomenon lever stroke
• Check that the machine does not deviate during constant-speed travel.
Related
(If the machine deviates even during constant-speed travel, carry out the related troubleshooting.)
Information

high idle. (Check cause 3 and confirm that the result is normal before
troubleshooting.)
Travel lever CO, NC valve output pressure
Defective adjustment or
Max. 0.55 MPa
1 malfunction of CO, NC Neutral
{Max. 5.5 kg/cm2}
valve
Min. 1.7 MPa

Full stroke on one side (Idle travel)
Presumed cause and
{Min. 17 kg/cm 2}
If the oil pressure cannot be set normally by adjustment, the CO, NC valve may have
a malfunction or may be adjusted defectively. Check the CO, NC valve directly.
Malfunction of main Since the servo-valve of main pump may have a malfunction, check it directly.
2
pump servo-valve (Test the servo-valve unit or measure its stroke.)
high idle.
Travel lever Differential pressure of jet sensor
Min. 1.5 MPa
Defective adjustment or Neutral
3 {Min. 15 kg/cm 2}
malfunction of jet sensor
Max. 0.2 MPa
Full stroke on one side (Idle travel)
{Max. 2 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the relief valve may have a
malfunction or the orifice may be defective. Check the relief valve and orifice directly.
30 PC600-8
H-21 Travel deviation is large during compound operation

Failure
• Travel deviation is large during compound operation
Phenomenon
• Check that the machine does not deviate while any work equipment is not operated.
Related
(If the machine deviates, carry out troubleshooting related to travel deviation.)
Information

troubleshooting.
R.H. work equipment control lever Shuttle valve outlet pressure
Malfunction of boom,
1 0 MPa
bucket PPC shuttle valve Neutral
{0 kg/cm2}
Min. 2.74 MPa
Boom or bucket full stroke
{Min. 28 kg/cm2}
troubleshooting.
Malfunction of arm, swing L.H. work equipment control lever Shuttle valve outlet pressure
2 PPC shuttle valve (arm
value in normalcy
0 MPa
side) Neutral
{0 kg/cm2}
Min. 2.74 MPa
Arm CURL • DUMP full stroke
{Min. 28 kg/cm2}
troubleshooting.
Malfunction of arm, swing Left work equipment control lever Shuttle valve outlet pressure
3 PPC shuttle valve (swing 0 MPa
side) Neutral
{0 kg/cm2}
Min. 2.74 MPa
Swing LEFT, RIGHT full stroke
{Min. 28 kg/cm2}
4 valve The travel shuttle valve of the control valve may malfunction. Check it directly.
(travel shuttle valve)
5 valve The straight travel valve of the control valve may malfunction. Check it directly.
(straight travel valve)
PC600-8 31
H-22 Travel speed or power is low

Failure
• Travel speed or power is low
Phenomenon
Related
Information

troubleshooting.
valve
Min. 2.74 MPa
FORWARD, REVERSE full stroke
{Min. 28 kg/cm2}
troubleshooting.
Malfunction of CO Travel lever Solenoid valve outlet pressure
2
cancel solenoid valve Neutral 0 MPa {0 kg/cm2}

Presumed cause and
Min. 2.74 MPa

Operated
{Min. 28 kg/cm2}
troubleshooting.
Malfunction of 2-stage Travel lever Solenoid valve outlet pressure
3
relief solenoid valve Neutral 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Operated
{Min. 28 kg/cm2}
troubleshooting.
Travel lever Travel relief pressure
Wrong adjustment or
4 malfunction of main relief 34.3 ± 1.47 MPa
valve Either side relieved
{350 ± 15 kg/cm2}
If the main relief valve is still abnormal after adjustment, its operation (on the high
pressure set side) may be defective. Check it directly.
32 PC600-8
H-23 Machine does not travel (only one track)

Failure
• Machine does not travel (only one track) (1) Machine does not travel in either direction.
Phenomenon
Related
—
Information

Presumed cause and
1 Since the parking brake of the travel motor may have a malfunction, check it directly.
motor (parking brake)
Internal defect of travel
2 Since the travel motor may have a defect in it, check it directly.
motor (body)
Internal defect of final Since the final drive may have a defect in it, check it directly. (The defect can be
3
drive judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.)
Failure
• Machine does not travel (only one track) (2) Machine does not travel forward or in reverse
Phenomenon
Related
Information

high idle.
1 Travel levers PPC valve output pressure
valve
FORWARD, REVERSE Min. 2.74 MPa
full stroke {Min. 28 kg/cm2}
Presumed cause and
Defective travel control Since the suction valve of the travel control valve may have a malfunction, check it
3
valve (suction valve) directly. (The suction valve can be checked by replacing it with normal one.)
high idle.
Malfunction of travel Travel levers Travel relief pressure
4
motor (safety valve)
Relieved on one side 34.3 ± 1.47 MPa
(Direction in which machine does not travel) {350 ± 15 kg/cm2}
Since the counterbalance valve of the travel motor may have a malfunction, check it
5 motor
directly.
(counterbalance valve)
PC600-8 33
H-24 Travel speed does not change

Failure
• Travel speed does not change
Phenomenon
• Check that the Lo and Hi travel speeds are normal.
Related • The travel speed selection system has the automatic speed changing function. If the oil pressure rises
Information above 33.4 MPa {340 kg/cm2} during travel, the travel speed is changed to Lo even while the machine
is traveling at Hi (Hi is still displayed on the monitor panel).

Presumed cause and
high idle.
Malfunction of travel Travel speed select switch Solenoid valve outlet pressure
1 speed select solenoid
valve Lo 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Hi
{Min.28 kg/cm2}
Malfunction of travel Since the servo mechanism of the travel motor may have a malfunction, check it
2
motor (servo mechanism) directly.
34 PC600-8
H-25 Upper structure does not swing

Failure
• Upper structure does not swing (1) Upper structure swings in neither direction.
Phenomenon
• Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out
Related troubleshooting related to it.)
Information • When carrying out the following troubleshooting, set the swing lock switch in OFF and the working
mode in the P mode.

troubleshooting.
Malfunction of swing L.H. work equipment control lever Solenoid valve outlet pressure
1 holding brake solenoid
valve Neutral (after 10 seconds or more) 0 MPa {0 kg/cm 2}
Operated to swing Min. 2.74 MPa
(in either direction) {Min. 28 kg/cm2}
Presumed cause and
Malfunction of swing
2 The parking brake of the swing motor may malfunction. Check it directly.
troubleshooting.
L.H. work equipment control lever Swing relief pressure
Wrong adjustment or
3 malfunction of swing Swing relief 29.91 ± 0.98 MPa
motor (safety valve) (in either direction) {305 ± 10 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction.
check the safety valve directly.
Swing motor (motor unit)
4 The motor unit of the swing motor may have a defect in it. Check it directly.
defective internally
Swing machinery Swing machinery may have a defect in it. Check it directly. (The swing machinery can
5
defective internally be checked by abnormal sound, abnormal heating, metal dust in the drained oil, etc.)
Failure
• Upper structure does not swing (2) Upper structure does not swing in only one direction.
Phenomenon
Information • When carrying out the following troubleshooting, set the swing lock switch in OFF and the working
mode in the P mode.

troubleshooting.
valve (swing circuit)
Min. 2.74 MPa

Swing RIGHT, LEFT full stroke
Presumed cause and
{Min.28 kg/cm 2}
2 The spool of the swing control valve may malfunction. Check it directly.
Malfunction of swing The suction valve of the swing control valve may malfunction. Check it directly.
3 control valve (The suction valves of the right and left swing control valves can be checked by
(suction valve) exchanging them with each other and seeing the change of the phenomenon.)
The suction valve of the swing motor may malfunction. Check it directly.
4 (The suction valves of the right and left swing motors can be checked by exchanging
motor (suction valve)
them with each other and seeing the change of the phenomenon.)
The check valve of the swing motor may malfunction. Check it directly.
5 (The check valves of the right and left swing motors can be checked by exchanging
motor (check valve)
PC600-8 35
H-26 Swing speed or acceleration is low

Failure (1) Swing speed or acceleration is low in both direc-
• Swing speed or acceleration is low
Phenomenon tions.
Information • When carrying out the following troubleshooting, set the working mode in the P mode and turn the
swing lock switch OFF.

troubleshooting.
1 Leakage in swing motor
L.H. work equipment control lever Leakage from swing motor
Swing relief (in either direction) Max. 10 l/min

Presumed cause and
troubleshooting.
Wrong adjustment or
Swing machinery may have a defect in it. Check it directly. (The swing machinery
Swing machinery
5 can be checked by abnormal sound, abnormal heating, metal dust in the drained oil,
etc.)
Failure (2) Swing speed or acceleration is low in only one direc-

• Swing speed or acceleration is low
Phenomenon tion.
Information • When carrying out the following troubleshooting, set the working mode in the P mode and turn the
swing lock switch OFF.

troubleshooting.
Min. 2.74 MPa

Presumed cause and
{Min. 28 kg/cm2}
Malfunction of swing The suction valve of the swing control valve may malfunction. Check it directly. (The
3 control valve suction valves of the right and left swing control valves can be checked by exchang-
(suction valve) ing them with each other and seeing the change of the phenomenon.)
motor (check valve)
36 PC600-8
H-27 Upper structure overruns excessively when it stops swinging

Failure • Upper structure overruns excessively when it (1) Upper structure overruns excessively when it stops
Phenomenon stops swinging swinging in both directions.
Related
—
Information

troubleshooting.

Presumed cause and
Wrong adjustment or
troubleshooting.
2 Leakage in swing motor
L.H. work equipment control lever Leakage from swing motor
Swing relief (in either direction) Max. 10 l/min
Failure • Upper structure overruns excessively when it (2) Upper structure overruns excessively when it stops
Phenomenon stops swinging swinging in only one direction.
Related
Information

troubleshooting.
Min. 2.74 MPa

Presumed cause and
{Min. 28 kg/cm 2}
The suction valve of the swing control valve may malfunction. Check it directly.
Malfunction of swing con-
3 (The suction valves of the right and left swing control valves can be checked by
trol valve (suction valve)
exchanging them with each other and seeing the change of the phenomenon.)
motor (check valve)
PC600-8 37
H-28 Large shock is made when upper structure stops swinging

Failure • Large shock is made when upper structure (1) Large shock is made when the upper structure stops
Phenomenon stops swinging swinging in both directions.
Related • When carrying out the following troubleshooting, set the working mode in the P mode and turn the
Information swing lock switch OFF.

troubleshooting.
valve Neutral (After 7 seconds or more) 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Operated to swing (in either direction)
{Min. 28 kg/cm2}
Presumed cause and
troubleshooting.
Wrong adjustment or
3 malfunction of swing 29.91 ± 0.98 MPa
motor (safety valve) Swing relief (in either direction)
{305 ± 10 kg/cm2}
Check the safety valve directly.
Swing machinery
etc.)
Failure • Large shock is made when the upper struc- (2) Large shock is made when the upper structure stops
Phenomenon ture stops swinging. swinging in only one direction.
Related • When carrying out the following troubleshooting, set the working mode in the P mode and turn the
Information swing lock switch OFF.

troubleshooting.
Presumed cause and
Malfunction of left PPC L.H. work equipment control lever PPC valve output pressure
1
valve (swing circuit) Neutral 0 MPa {0 kg/cm2}
Min. 2.74 MPa
{Min. 28 kg/cm2}
38 PC600-8
H-29 Large abnormal sound is made when upper structure stops swinging
Failure • Large abnormal sound is made when upper (1) Large abnormal sound is made when the upper
Phenomenon structure stops swinging structure stops swinging in both directions.
Related
—
Information

Malfunction of back
1 pressure compensation The back pressure compensation valve may malfunction. Check it directly.
valve
Presumed cause and
troubleshooting.
Wrong adjustment or
2 malfunction of swing 29.91 ± 0.98 MPa
motor (safety valve) Swing relief (in either direction)
{305 ± 10 kg/cm2}
Check the safety valve directly.
Swing machinery
etc.)
Failure • Large abnormal sound is made when upper (2) Large abnormal sound is made when the upper
Phenomenon structure stops swinging structure stops swinging in only one direction.
Related
—
Information

Presumed cause and
Malfunction of swing The suction valve of the swing control valve may malfunction. Check it directly.
1 control valve (The suction valves of the right and left swing control valves can be checked by
(suction valve) exchanging them with each other and seeing the change of the phenomenon.)
PC600-8 39
H-30 Hydraulic drift of swing is large

Failure
• Hydraulic drift of swing is large (1) While the swing holding brake is applied.
Phenomenon
Related
• When carrying out the following troubleshooting, set the working mode in the P mode.
Information

Presumed cause and
troubleshooting.
valve Neutral (After 5 seconds or more) 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Operated to swing (in either direction)
{Min. 28 kg/cm2}
Failure
• Hydraulic drift of swing is large (2) While the swing holding brake is released.
Phenomenon
Related
—
Information


Presumed cause and
2 control valve The suction valve of the swing control valve may malfunction. Check it directly.
(suction valve)
3 The safety valve of the swing motor may malfunction. Check it directly.
motor (safety valve)
4 The suction valve of the swing motor may malfunction. Check it directly.
5 The check valve of the swing motor may malfunction. Check it directly.
motor (check valve)
40 PC600-8
PC600-8 41
©2006 KOMATSU
All Rights Reserved
42
UEN00453-00
HYDRAULIC EXCAVATOR
PC600-8
PC600LC-8
PC600-8 K50001 and up

40 Troubleshooting
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode).................................................................................................................... 3

Method of using troubleshooting chart ........................................................................................................... 3
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 8
S-3 Engine does not pick up smoothly ......................................................................................................... 12
S-4 Engine stops during operations.............................................................................................................. 13
S-5 Engine does not rotate smoothly............................................................................................................ 14
S-6 Engine lacks output (or lacks power) ..................................................................................................... 15
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
S-14 Coolant temperature becomes too high (overheating)......................................................................... 24
S-15 Abnormal noise is made ...................................................................................................................... 25
S-16 Vibration is excessive........................................................................................................................... 26
PC600-8 1
2 PC600-8
Troubleshooting of engine (S-mode)

Method of using troubleshooting chart
The troubleshooting chart consists of the "ques-
tions", "check items", "causes", and "troubleshoot-
ing" blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right. The items in A are basic ones. The items
in B can be drawn from the user or operator,
depending on their level.
[Check items]
Simple check items used by the serviceman to
narrow the causes. They correspond to C in the
chart on the right.
[Causes]
Items to be narrowed from the questions and
check items. The serviceman narrows down the
probable causes from A, B, and C.
[Troubleshooting]
Items used to find out the true cause by verifying
the narrowed causes finally in order from the
most probable one by applying troubleshooting
tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and 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.)
PC600-8 3
<Example of troubleshooting> Exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have
causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and
[Air cleaner clogging caution lamp is flashing].
4 PC600-8
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
PC600-8 5
S-1 Starting performance is poor
General causes why starting performance is poor Causes
• Defective electrical system
Cracked EGR cooler (Coolant in exhaust pipe)

• Insufficient supply of fuel
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective alternator (generator section)

Defective alternator (regulator section)
• Insufficient intake of air
Defective contact of valve, vale seat
Stuck, seized supply pump plunger
Defective intake air heater system

Clogged feed pump gauze filter
• Improper selection of fuel
Defective, deteriorated battery

Clogged air cleaner element
Clogged fuel filter, element

Worn piston ring, cylinder
• Coolant in exhaust pipe
a The common rail fuel injection system (CRI) recognizes the fuel
Defective injector
injection timing electrically. Accordingly, even if the starting
operation is carried out, the engine may not start until the crankshaft
revolves 2 turns at maximum. This phenomenon does not indicate
a trouble, however.
Confirm recent repair history

Degree of use of
machine Operated for long period EE EE E
Became worse gradually Q Q w w Q Q
Starting performance
Engine starts easily when warm w
Questions
Non-specified fuel is being used Q Q Q Q w

Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual w w w Q Q
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge (if monitor is
installed) w w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Starting motor cranks engine slowly Q w
While engine is If air bleeding plug of fuel filter is removed, fuel does not
flow out w w
cranked with starting
Check items
motor If spill hose from injector is disconnected, little fuel spills w

When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows
out (*1) q
When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Troubleshooting
Inspect fuel filter, strainer directly q

Inspect feed pump gauze filter directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*2)” q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Is voltage 20 – 30 V between alternator terminal R and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
For *1 and *2, see the next page. Remedy

Clean
Clean
Clean
Clean
6 PC600-8
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out.
A little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, how-
ever, it is not a problem.
*2: See failure codes [CA559] and [CA2249] in troubleshooting by failure code (display of codes) (Part 2).
PC600-8 7
S-2 Engine does not start
a) Engine does not turn Causes

General causes why engine does not turn
Cracked EGR cooler (Coolant in exhaust pipe)
Defective starting motor (safety relay section)

• Internal parts of engine seized
Defective connection of battery terminal
Defective starting motor (motor section)

→See “S-4 Engine stops during operations.”
Defective hydraulic pump or PTO

Defective or deteriorated battery
• Water hammer caused by coolant which entered cylinder
Defective starting circuit wiring

Broken flywheel ring gear
• Defective electrical system
Defective starting switch

Defective battery relay
• Defective hydraulic pump or PTO

Degree of use of
Questions
Operated for long period EEE

machine
Condition of horn when Horn does not sound Q Q
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q
Check items
When starting switch is

Speed of rotation is low Q w
turned to START, start- Makes grating noise w w
ing pinion moves out, Soon disengages again w
but
Makes rattling noise and does not turn w Q Q
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1). q
Inspect flywheel ring gear directly q

Carry out troubleshooting on H-mode
Carry out troubleshooting on E-mode
Troubleshooting
There is not voltage (20 – 30 V) between battery relay terminal M and

q
terminal E
Turn starting switch When terminal B and terminal C of starting switch are connected,
q
OFF, connect cord, and engine starts
carry out troubleshoot- When terminal B and terminal C at safety relay outlet are connected,
ing at ON q
engine starts
Even if terminal B and terminal C at safety relay outlet are connected,

q
engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
For *1, see the next page. Remedy

—
8 PC600-8

PC600-8 9
b) Engine turns but no exhaust smoke comes out Causes
Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke comes out
• Fuel is not being supplied

Wrong connection of supply pump PCV

• Supply of fuel is extremely small
Seized, abnormally worn feed pump
Defective operation of flow damper

• Improper selection of fuel (particularly in winter)
Broken supply pump shaft, key
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Degree of use of
Questions
Operated for long period EEE

machine
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w EE
Replacement of filters has not been carried out according to Operation and Main-
w w E Q
tenance 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 not fuel in it w w
Fuel is leaking from fuel piping w
Check items

While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q Q w Q
cranked with start- out
ing motor If spill hose from injector is disconnected, little fuel spills Q w w w w Q
Inspect fuel filter directly q
q
Troubleshooting
Inspect feed pump gauze filter directly

Inspect feed pump directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” q q q
Carry out troubleshooting according to “Abnormality in PCV1 (*2) or Abnormality in
q
PCV2 (*3)”
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Clean
Add
*1: Failure code [CA559] and failure code [CA2249]

10 PC600-8
c) Exhaust smoke comes out but engine does not start (fuel is being injected) Causes
Worn dynamic valve system (Valve, rocker lever, etc.)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does not start
• Lack of rotating force due to defective electrical system
Leaking or clogged fuel system, entry of air

Defective intake air heater system

Clogged injector, defective spray
Worn piston ring, cylinder liner
Defective, deteriorated battery

Clogged fuel filter, strainer

Use of improper fuel

Degree of use of machine Operated for long period E EE E
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used QQ

Replacement of filters has not been carried out according to Operation and Maintenance
w ww
Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not indicate
w
normally (if monitor is installed)
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained ww
When fuel filter is removed, there is not fuel in it w
When priming pump is operated, it makes no reaction or it is heavy wQQ
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
While engine is cranked If air bleeding plug of fuel filter is removed, fuel does not flow out Q ww
with starting motor, If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of some
w
cylinders is low

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

When injector unit is tested, spray condition is bad q
Coolant temperature gauge does not indicate normally (if coolant temperature gauge is
q
installed)
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
Clean
Clean
PC600-8 11
S-3 Engine does not pick up smoothly
General causes why engine does not pick up smoothly Causes
Defective operation of flow damper (Large leakage from injector)

Seized turbocharger, interference of turbocharger

• Defective condition of fuel spray

Defective contact of valve and valve seat
• Controller is controlling in derate mode (limiting injection rate (output)
Clogged injector, defective spray

because of an error in electrical system)


Improper valve clearance
• EGR valve is stuck open
(There is much EGR gas and intake of air is insufficient)l
Stuck EGR valve

Degree of use of
Operated for long period EEE E E E
machine
Questions
Engine pick-up suddenly became worse Q w Q Q Q

Non-specified fuel is being used w w w w
w w w
nance Manual
Oil must be added more frequently w
Rust and water are found when fuel tank is drained w w
Q w
some cylinders is low
Color of exhaust Blue under light load w
Check items
gas Black w Q w w
When engine is cranked, interference sound is generated 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
Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” q
Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
q q
not change
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
Clean
Clean
Clean
Clean

12 PC600-8
S-4 Engine stops during operations
General causes why engine stops during operations Causes
Broken dynamic valve system (valve, rocker arm, etc.)

• Seized parts inside engine

• There is overheating
Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Defective hydraulic pump or PTO

• Defective hydraulic pump or PTO
Broken supply pump shaft, key

Leaking, clogged fuel piping
Broken, seized feed pump

Broken, seized gear train
Degree of use of machine Operated for long period EE
Abnormal noise was heard and engine stopped suddenly w w w w Q w Q w
Condition when engine Engine overheated and stopped w Q
Questions
stopped Engine stopped slowly w Q Q

There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
w w
nance Manual
Fuel level monitor indicates low level (if monitor is installed) w
Rust and water are found when fuel tank is drained w w
Metal particles are found when oil is drained w w Q Q
Check items
Does not turn at all w w

When engine is cranked Turns in opposite direction w
by hand Moves by amount of gear backlash w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Carry out troubleshooting on H-mode
Inspect piston, connecting rod directly q
Inspect crankshaft bearing directly q

Troubleshooting
Inspect gear train directly q
Inspect feed pump directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” q q

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
—
Add
PC600-8 13
S-5 Engine does not rotate smoothly
General causes why engine does not rotate smoothly Causes
Defective operation of flow damper (Large leakage from injector)

• Air in fuel system
• Defective speed sensor (Error at degree that it is not indicated)
• Defective EGR valve
Clogged injector, defective spray (dirt in injector)

• Defective bypass valve
Defective Ne speed sensor, wiring harness

Defective G speed sensor, wiring harness

Defective operation of bypass valve
Defective operation of EGR valve

Low setting of low idle speed

Degree of use of machine Operated for long period EE EE
Occurs at a certain speed range Q Q Q Q Q
Questions
Occurs at low idle w Q Q Q Q Q Q Q

Condition of hunting
Occurs even when speed is raised Q Q Q Q Q
Occurs on slopes w Q Q
w w
nance Manual
Check items
Rust and water are found when fuel tank is drained Q Q

Carry out troubleshooting according to “Abnormality in bypass valve servo (*2)” q
Troubleshooting

q q
not change
Carry out troubleshooting according to “Abnormality in engine Ne speed sensor
q
(*3)”
Carry out troubleshooting according to “Abnormality in engine Bkup speed sensor
q
(*4)”
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
Clean
Add

*3: Failure code [CA689]
*4: Failure code [CA778]
14 PC600-8
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output Causes
Defective installation of charge pressure sensor (air leakage)

Defective fuel temperature sensor, wiring harness

Defective charge pressure sensor, wiring harness
Clogged injector, defective spray (dirt in injector)

• Defective spray condition of fuel
Defective drive of injector (signal, solenoid)


Air leakage from air intake piping

Leaking, clogged fuel piping

→See “S-14 Coolant temperature becomes too high (Overheating)”

• Controller is controlling in derate mode (limiting injection rate (out-
put) because of an error in electrical system)

Degree of use of
machine
Operated for long period E E E E E
Q Q Q Q
Questions
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
nance Manual
w
Engine oil must be added more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Black w w
Color of exhaust gas
Blue under light load w
w
Check items

High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load is
applied
w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting

not change
q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to “Abnormality in charge pressure sensor (*2)” q
Carry out troubleshooting according to “Abnormality in fuel temperature sensor (*3)” q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Remedy
Clean
Clean
Clean

PC600-8 15
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head


• Excessive injection of fuel
Clogged fuel spill piping (on cylinder head side)

• Defective condition of fuel injection


Improper fuel injection pressure

→See “S-14 Coolant temperature becomes too high (Overheating)”
Improper fuel injection timing

Crushed, clogged muffler
Abnormally worn injector

Clogged, seized injector
• Controller is controlling in derate mode (limiting injection rate
(output) because of an error in electrical system)
Stuck EGR valve

• EGR valve is stuck open (There is much EGR gas and intake of air is
insufficient)

Degree of use of machine Operated for long period E E E E E
Suddenly became black w Q Q Q Q
Color of exhaust gas Gradually became black w Q Q
Questions
Blue under light load w

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
Q w
Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w
When turbocharger is rotated by hand, it is found to be heavy q
q q
Troubleshooting
When compression pressure is measured, it is found to be low

When muffler is removed, exhaust sound improves q
Carry out troubleshooting according to “No-pressure feed by supply pump (*2)” q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
q
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*3)” q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Remedy
Clean

16 PC600-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive Causes
Turbocharger
• Abnormal consumption of oil
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
• Long-time operation of engine at low idle or high idle (Do not run engine
at idle for more than 20 minutes continuously)
Dust sucked in from intake system
Oil leakage from EGR valve stem

Clogged breather, breather hose
Worn seal at turbocharger end

• External leakage of oil
Oil leakage from oil drain plug

Worn, damaged rear oil seal
Oil leakage from oil cooler
Oil leakage from oil piping

• Wear of pats in lubrication system
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of use of
Questions
Operated for long period EEEE E

machine
Oil consumption suddenly increased w Q
Oil must be added more frequently Q w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber of machine is high w
Exhaust smoke is blue under light load Q w w
Amount of blow-by Excessive Q Q w w
gas None w
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is found to be dirty abnor-
q
mally
Troubleshooting
Excessive play of turbocharger shaft q q

When EGR valve is removed, exhaust port is found to be dirty with oil q
Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Remedy
Clean
PC600-8 17
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly Causes
Clogged turbocharger lubrication drain tube

• Entry of exhaust gas into oil due to internal wear
Defective turbocharger turbine side seal

• Clogging of lubrication passage
Clogged breather, breather hose

• Use of improper fuel
Defective oil filter safety valve

• Use of improper oil
Worn valve, valve guide

Worn EGR valve guide
Exhaust smoke is bad

• Operation under excessive load
Clogged oil cooler

Clogged oil filter
Degree of use of
Operated for long period E E E E
Questions
machine
Non-specified fuel is being used Q
Engine oil must be added more frequently Q w
Even when engine oil temperature rises, oil filter clogging monitor indi-
w Q
cates clogging (if monitor is installed)
Metal particles are found when oil is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Color of exhaust gas Blue under light load w
Check items
color Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

When EGR valve is removed, exhaust port is found to be dirty with oil q
Troubleshooting

See S-7
Inspect breather and breather hose directly q

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
Replace
Remedy
Clean
Clean
Clean
—
18 PC600-8
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes

• Leakage of fuel
• Defective condition of fuel injection (fuel pressure, injection timing)
• Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

Degree of use of
Questions
Operated for long period EE E

machine
More than for other machines of same model Q Q Q Q
Condition of fuel
Gradually increased Q Q
consumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Exhaust smoke Black Q Q Q Q
color White Q
Remove and inspect head cover directly q
Inspect feed pump oil seal directly q
Troubleshooting

When a cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to “Abnormality in coolant temperature
q
sensor (*2)”
Confirm with monitoring function on machine monitor q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy

PC600-8 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
General causes why oil is in coolant Causes
Damaged cylinder liner O-ring, holes caused by pitting

• Internal leakage in lubrication system
• Internal leakage in cooling systeml
Insufficient protrusion of cylinder liner

Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring

Questions
Degree of use of machine Operated for long period E E

Suddenly increased Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check
items
Pressure-tightness test of cylinder head shows there is leakage q

Troubleshooting
Inspect cylinder block, liner directly q q
Inspect cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy
20 PC600-8
S-12 Oil pressure drops
General causes why oil pressure drops Causes
Defective oil pressure sensor, wiring harness

• Leakage, clogging, wear in lubrication system
Leaking, crushed, clogged hydraulic piping
Defective oil level sensor, wiring harness

• Defective oil pressure control
• Improper selection of fuel (improper viscosity)
Clogged, broken pipe in oil pan
Defective oil pump relief valve
Leaking EGR hydraulic piping

• Deterioration of oil due to overheatingl
Clogged strainer in oil pan
Defective EGR oil pump

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Degree of use of
Operated for long period E E E
Questions
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and
w
Maintenance Manual
Indicates pressure drop at low idle w Q Q
Oil pressure Indicates pressure drop at low, high idle Q w w w Q Q Q
monitor
(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q Q
Metal particles are found in oil filter q

Inspect oil pan strainer, pipe directly q q
Oil pump rotation is heavy, there is play in oil pump q
Troubleshooting
Valve and spring of oil pump relief valve are fatigued, damaged q
See S-13
Inspect oil filter directly q

Relief valve of EGR oil pump is damaged, oil leaks from it q
Inspect EGR hydraulic piping directly q
Carry out troubleshooting according to “Abnormality in oil pressure sensor
q
(*1)”
If oil level sensor is replaced, oil pressure monitor indicates normally q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
Clean
Clean
—
Add
PC600-8 21
S-13 Oil level rises (Entry of coolant or fuel)
General causes why oil level rises Causes
Clogged water pump drain hole (breather hole), defective seal

• Coolant in oil (milky)
• Fuel in oil (smells diluted diesel fuel)
Damaged cylinder liner O-ring, holes caused by pitting

a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”
Cracked EGR cooler (Entry of coolant)

Fuel leakage inside head cover
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block
Defective thermostat seat

Defects in supply pump
Questions
Degree of use of
Operated for long period EE E
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q w
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q w
When engine is started, drops of water come from muffler Q Q
When radiator cap is removed and engine is run at low idle, an abnormal num-
w Q
ber of bubbles appear, or coolant spurts back
Check items
Exhaust smoke is white Q Q

Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant comes out w
Oil level in damper chamber of machine is low w
Oil level in hydraulic tank of machine is low
When EGR cooler outlet gas piping is removed, coolant containing antifreeze
q
flows out (*1)
Troubleshooting
Remove and inspect head cover directly q

Inspect cylinder block, liner directly q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
22 PC600-8

PC600-8 23
S-14 Coolant temperature becomes too high (overheating)
General causes why coolant temperature becomes too high Causes
Damaged cylinder liner O-ring, hole caused by pitting

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
External leakage of coolant from EGR cooler

• Problem in coolant circulation system
Defective radiator cap (pressure valve)

Defective coolant temperature gauge
Defective fan drive pump or motor

Defective operation of thermostat
Clogged, crushed radiator fins
Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of use of
Operated for long period E E E E E
machine
Questions
Condition of Sudden overheated Q Q w

overheating Always tends to overheat Q w w
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Q w
Engine oil level has risen, oil is milky w Q
Fan belt tension is low
When fan pulley is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard are clogged with dirt or mud w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration
Inspect EGR cooler for coolant leakage q

Inspect cylinder liner directly q
Inspect oil cooler directly q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

When operation of thermostat is carried out, it does not open at cracking tempera-
q
ture
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
When coolant temperature is measured, it is fount to be normal q
Inspect fan rotation q
Inspect fan pump oil pressure q
Check, replace
Remedy
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Add
24 PC600-8
S-15 Abnormal noise is made
General causes why abnormal noise is made Causes
Deformed cooling fan, loose fan belt, interference of fan belt

• Abnormality due to defective parts
Defective inside of muffler (dividing board out of position)

Leakage of air between turbocharger and cylinder head
• Abnormal combustion
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
• Air sucked in from intake system
(abnormality in coolant temperature sensor)

Excessive wear of piston ring, cylinder liner
a Judge if the noise is an internal noise or an external noise before
Removed, seized gear train bushing

starting troubleshooting.
Cracked, leaking EGR gas piping

a The engine is operated in the low-temperature mode while it is not

Improper gear train backlash
warmed up sufficiently. Accordingly, the engine sound becomes
Clogged, seized injector

a little larger. This does not indicate abnormality, however.
Dirt caught in injector

a When the engine is accelerated, it is operated in the acceleration
mode and its sound becomes a little larger for up to about 3
seconds. This does not indicate abnormality, however.

Degree of use of
Operated for long period E
machine
Questions
Condition of Gradually occurred Q Q

abnormal noise Sudden occurred Q Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around EGR gas piping w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
When exhaust manifold is touched immediately after starting engine, temperature

w Q
of some cylinders is low
Color of exhaust Blue under light load w
gas Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is fount to be heavy q
Inspect EGR gas piping directly q
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q q
does not change
Abnormal noise is heard only when engine is started q
Confirm with monitoring function on machine monitor q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
PC600-8 25
S-16 Vibration is excessive
General causes why vibration is excessive Causes
Stuck dynamic valve system (valve, rocker lever)

• Defective parts (abnormal wear, breakage)
Loose engine mounting bolts, broken cushions

Broken output shaft, parts in damper on PTO
Worn main bearing, connecting rod bearing
• Misalignment between engine and chassis
• Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out
Improper gear train backlash

troubleshooting for “S-15 Abnormal noise is made”, too..
Improper injection timing

Worn camshaft bushing
Degree of use of
Questions
Operated for long period E E

machine
Condition of Suddenly increased Q
vibration Gradually increased Q Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q

Vibration follows engine speed Q Q
Exhaust smoke is black w

Troubleshooting
Inspect main bearing and connecting rod bearing directly q

Inspect gear train directly q
Inspect camshaft bushing directly q
Confirm with monitoring function on machine monitor q
Inspect engine mounting bolts and cushions directly q
Inspect output shaft or inside of damper directly
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
—
26 PC600-8
PC600-8 27
©2006 KOMATSU
All Rights Reserved
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UEN00447-00

Machine model Serial number

PC600-8 K50001 and up

General information on troubleshooting ............................................................................................................... 2

General information on troubleshooting

Sequence of events in troubleshooting

Checks before troubleshooting

4. Check hydraulic oil strainer — Clean, drain

5. Check swing machinery oil level — Add oil

1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

1. Check for abnormal noise, smell — Repair

1. Check battery voltage (engine stopped) 20 – 30V Replace

3. Check for discolored, burnt, exposed wiring — Replace

Classification and procedures of troubleshooting

Procedure for troubleshooting

Failure-looking Phenomenon and Troubleshooting No.

Connection table for connector pin numbers

Part No.: 08055-00282 Part No.: 08055-00292

Part No.: 08055-00381 Part No.: 08055-00391

Part No.: 08055-00481 Part No.: 08055-00491

Part No.: 08055-10681 Part No.: 08055-10691

Part No.: 08055-10881 Part No.: 08055-10891

Part No.: 08055-11281 Part No.: 08055-11291

Part No.: 08055-11481 Part No.: 08055-11491

SWP type connector

Part No.: 08055-11681 Part No.: 08055-11691

No.of M type connector

Part No.: 08056-00271 Part No.: 08056-00281

Part No.: 08056-00371 Part No.: 08056-00381

Part No.: 08056-00471 Part No.: 08056-00481

Part No.: 08056-00671 Part No.: 08056-00681

Part No.: 08056-00871 Part No.: 08056-00881

Part No.: 08056-10871 Part No.: 08056-10881

Part No.: 08056-11071 Part No.: 08056-11081

Part No.: 08056-11271 Part No.: 08056-11281

Part No.: 08056-11671 Part No.: 08056-11681

Part No.: 08056-11272 Part No.: 08056-11282

Part No.: 08056-11672 Part No.: 08056-11682

No.of MIC type connector

No.of MIC type connector

No.of AMP040 type connector

— Housing part No.: 79A-222-3430 (Q’ty: 5)

— Housing part No.: 79A-222-3440 (Q’ty: 5)

— Housing part No.: 79A-222-3450 (Q’ty: 5)

— Housing part No.: 79A-222-3460 (Q’ty: 5)

a Terminal part No.: 79A-222-3470 (No relation with number of pins)

No.of AMP070 type connector

— Part No.: 08195-10210

— Part No.: 08195-12210

— Part No.: 08195-14210

— Part No.: 08195-18210

— Part No.: 08195-20210

No.of L type connector

No.of Connector for PA

No.of Bendix MS connector

No.of KES 1 (Automobile) connector

Part No.:08027-10310 Part No.:08027-10360